OPERATING MANUAL

TW45
Drive
03/2023

6231003860
2 Company and contact information

Company and contact

information
All rights reserved
© Copyright by TK Aufzugswerke GmbH

Proprietary notice ISO 16016

Printed in Germany
This document – including excerpts – may only be reprinted or otherwise
copied with the express approval in writing of TK Aufzugswerke GmbH.
Any form of duplication, dissemination or storage on data media in any form
that is not authorised by TK Aufzugswerke GmbH represents a violation of
prevailing copyright law and shall lead to legal proceedings.

Subject to change without notice

We expressly reserve the right to make changes of a technical nature for the
purpose of improving our products or enhancing the safety standard – includ-
ing without a separate announcement.

Colour coding
The colour coding of the components used in our documents is exclusively for
documentation purposes.
You can find out about the colours for your products from your TK Aufzug-
swerke GmbH sales partner.

Form of address
In the interest of better legibility, we use exclusively the masculine grammat-
ical form, for example "fireman". At the same time, it always refers to human
genders: male, female, diverse.

Issued by
TK Aufzugswerke GmbH
Bernhäuser Straße 45
73765 Neuhausen a. d. F.
Germany
Tel: +49 7158/12-0
E-mail: Doku.elevator.plant.de@tkelevator.com
Internet: eli.tkelevator.com

TK Elevator
BA, TW45 | 6231003860 | 03/2023
Table of contents 3

Table of contents
1 About these instructions. ...........................................................................  6
1.1 Guide to layout. ...........................................................................................................................................................  6

2 Safety. ............................................................................................................  7
2.1 Warning notes. ............................................................................................................................................................. 7
2.1.1 Structure. ................................................................................................................................................................  7
2.1.2 Indications of danger to persons........................................................................................................................  7
2.1.3 Indication of possible damage to property. .....................................................................................................  7
2.2 Safety requirements...................................................................................................................................................  8
2.2.1 Area of applicability. .............................................................................................................................................  8
2.2.2 Basic requirements for safety.............................................................................................................................  8
2.2.3 Obligations of the operating company and installation firm. .......................................................................  8
2.2.4 Duties of personnel. ..............................................................................................................................................  8
2.2.5 Dangers in handling the drive. ............................................................................................................................ 9
2.3 Warranty and liability. ............................................................................................................................................... 10
2.3.1 Structural modification of the product. ..........................................................................................................  10
2.3.2 Use in line with intended use.............................................................................................................................  10
2.4 10 rules for health and safety at work. ................................................................................................................... 11
2.5 Personal protective equipment............................................................................................................................... 12

3 Description. .................................................................................................. 13
3.1 Standards and legal requirements. ........................................................................................................................ 13
3.2 Product Group TW Machines. ................................................................................................................................. 13
3.3 Product. ....................................................................................................................................................................... 13
3.3.1 Machine base frame. .........................................................................................................................................  20
3.3.2 Motor versions. .................................................................................................................................................... 23
3.3.3 Special versions. .................................................................................................................................................. 24
3.3.4 Standard version for machine in the machine room. ................................................................................... 24
3.3.5 Version with emergency brake, NBS............................................................................................................... 24
3.3.6 Version with earthquake safeguard complying with EN81-77. .................................................................. 25
3.3.7 Version for machine location in the shaft pit for ISIS1................................................................................. 25
3.4 Combination of versions / options. ....................................................................................................................... 26

4 Technology..................................................................................................  27
4.1 Mechanical data........................................................................................................................................................  27
4.1.1 Gear unit................................................................................................................................................................ 27
4.1.2 Brake. ..................................................................................................................................................................... 28
4.1.3 Encoder. ...............................................................................................................................................................  29
4.1.4 Traction sheave...................................................................................................................................................  30
4.1.5 Performance chart. ............................................................................................................................................  30
4.1.6 Motor versions. .................................................................................................................................................... 32
4.1.7 Load data - traction sheave shaft. ..................................................................................................................  34
4.1.8 Load data for upward horizontal / vertical rope pull direction..................................................................  34
4.1.9 Gear efficiency. .................................................................................................................................................... 35
4.1.10 Mass moment of inertia. ...................................................................................................................................  36
4.1.11 Weight...................................................................................................................................................................  36
4.1.12 Noise levels. .......................................................................................................................................................... 37
4.2 Dimensions.................................................................................................................................................................  38
4.2.1 Machine................................................................................................................................................................. 38

TK Elevator
BA, TW45 | 6231003860 | 03/2023
4 Table of contents

4.2.2 Machine base frame. .......................................................................................................................................... 42

5 Transportation and storage. ....................................................................  47

5.1 Packaging...................................................................................................................................................................  47
5.2 Transport....................................................................................................................................................................  48
5.3 Fork-lift truck transport. .........................................................................................................................................  48
5.4 Crane transport. ........................................................................................................................................................  48
5.5 Checking the delivery. ............................................................................................................................................. 49
5.6 Intermediate storage................................................................................................................................................ 50

6 Installation. ................................................................................................... 51
6.1 Setting up the machine base frame....................................................................................................................... 51
6.2 Aligning the machine. ............................................................................................................................................... 51
6.3 Mounting the frame with rope pulley. ..................................................................................................................  52
6.4 Mounting the rope guard. .......................................................................................................................................  54
6.5 Rope pulley on the machine base frame..............................................................................................................  55
6.6 Shift protection on the machine base frame. .....................................................................................................  55
6.7 Electrical connection. .............................................................................................................................................. 56
6.7.1 Connecting the machine.................................................................................................................................... 57
6.7.2 Connecting the motor line. ................................................................................................................................ 58
6.7.3 Connecting the posistor....................................................................................................................................  59
6.7.4 Connecting the brake. .......................................................................................................................................  59

7 Work on the product. ...............................................................................  60

7.1 Testing the brake...................................................................................................................................................... 60
7.2 Replacing the brake................................................................................................................................................... 61
7.2.1 Mayr brake............................................................................................................................................................  61
7.3 Checking the oil level. .............................................................................................................................................. 63
7.4 Lubrication. ................................................................................................................................................................ 63
7.5 Checking the backlash............................................................................................................................................. 65
7.6 Replacing the traction sheave................................................................................................................................ 66
7.7 Replacing the motor................................................................................................................................................. 68
7.8 Replacing the encoder. ............................................................................................................................................ 69
7.9 Checking for grease/oil leakage. ........................................................................................................................... 70
7.10 Blocking clamp. ..........................................................................................................................................................  71

8 Commissioning...........................................................................................  72
8.1 Work steps. ................................................................................................................................................................  72
8.2 Emergency operation. .............................................................................................................................................  72

9 Maintenance. ..............................................................................................  74

9.1 Standstill maintenance. ...........................................................................................................................................  74

10 Appendix......................................................................................................  75
10.1 Tightening torques. ..................................................................................................................................................  75
10.2 Manufacturer information. .....................................................................................................................................  75
10.2.1 Wachendorff encoder WDG100H_38-1024 - Data sheet. ...........................................................................  77
10.2.2 Verification of traction sheave calculation..................................................................................................... 78
10.2.3 mayr ROBA-duplostop Size 125 brake - installation and operating manual............................................ 79
10.2.4 mayr ROBA-duplostop Size 500 - 1800 brake - installation and operating manual. ...........................  95
10.2.5 SKINTOP MS-SC Mounting instructions........................................................................................................ 111
10.2.6 Wachendorff encoder WDG100H--xx-yyyy-ABN-I05-K3-D56 - assembly instructions.....................  112

TK Elevator
BA, TW45 | 6231003860 | 03/2023
Table of contents 5

10.2.7 Drehgeber Wachendorf WDG 100H - Datenblatt. ....................................................................................... 113

10.2.8 Drehgeber Wachendorf WDG 100H-XX-YYYY - Montageanleitung. ......................................................  125
10.2.9 Drehgeber Wachendorf WDG 100H-38-2048.pdf......................................................................................  126

TK Elevator
BA, TW45 | 6231003860 | 03/2023
 About these instructions
6 Guide to layout

1 About these instructions

1.1 Guide to layout
Sequence of actions involving several steps
ü Requirement for the sequence of actions (optional).
1. First action step.
2. Second action.
Interim result (optional)
3. Third action step.
Result of action (optional)

Sequence of actions involving independent steps

Action step.
Action step.
Action step.

Information

i Information must always be read and followed.

Reference
Chap. 1 P. 6

List
▪ Top item of a list
– Sub-item of a list
– Sub-item of a list
▪ Top item of a list
▪ Top item of a list

TK Elevator
BA, TW45 | 6231003860 | 03/2023
Safety
Warning notes 7

2 Safety
2.1 Warning notes
▪ Warning notes are intended for the protection of persons and property.
▪ Warning notes must be read and observed by every person who works on
the product.
▪ Warning notes precede activities that pose a hazard for people and the
product.

2.1.1 Structure
SIGNAL WORD AND SIGNAL COLOUR
Type and source of danger
Consequences if danger disregarded.
Measures to avert the danger.

2.1.2 Indications of danger to persons

DANGER
Danger with a high degree of risk!
If ignored, leads to death or serious injury.
Read and comply with the warning.

WARNING
Danger with a high degree of risk!
If ignored, may lead to death or serious injury.
Read and comply with the warning

CAUTION
Danger with a low degree of risk!
If ignored, may lead to minor or moderate injury.
Read and comply with the warning.

2.1.3 Indication of possible damage to property

NOTICE
Hazard with possible damage to property!
May lead to product function impairments or function loss.
Read and comply with the warning.

TK Elevator
BA, TW45 | 6231003860 | 03/2023
 Safety
8 Safety requirements

2.2 Safety requirements

This document contains important information for safe operation of the
product.
Keep this document and all other applicable documents at the location of
use for the entire working life of the product.

2.2.1 Area of applicability

This document applies only to the product described here.

Other applicable documents

▪ International occupational health and safety regulations

2.2.2 Basic requirements for safety

▪ All existing safety devices are to be tested regularly in accordance with
the maintenance schedule.
▪ This document, in particular the chapter entitled "Safety", together with
the warnings and all other applicable documents, must be followed by all
persons who work with the product.
▪ In addition to this document, the rules at the location of use with regard to
environmental protection and the occupation health and safety and acci-
dent prevention regulations must be followed.
▪ All safety and hazard warnings on the installation must be kept in legible
condition.
▪ Safety information and instructions required by law must be displayed to
users in such a way that they are clearly visible.
▪ A requirement for safe handling and non-disruptive operation of this
product is knowledge of the fundamental safety regulations.

2.2.3 Obligations of the operating company and installation

firm
Only deploy trained and instructed qualified personnel.
Provide personnel with the required personal protective equipment.
Check personnel at regular intervals to ensure that they follow safety-
conscious work practices and comply with national provisions.
Make all other applicable documents as well as this document available to
personnel.

2.2.4 Duties of personnel

Clearly establish all areas of responsibility prior to any activity.
Always wear the personal protective equipment made available to you.
Prior to work, make people aware of the dangers of electrical current.

TK Elevator
BA, TW45 | 6231003860 | 03/2023
Safety
Safety requirements 9

2.2.5 Dangers in handling the drive

DANGER
Residual voltage after switching off the elevator installation!
Electric shock that can lead to death or severe injury.
Perform work on energised parts of the drive only after the waiting
period and/or when the DC link voltage is less than 60 V (check with a
measuring instrument)

WARNING
Inadequate connection
Electric shock. Damage to drive.
Earth the motor and brake magnet in accordance with country-specific
regulations.
Electrical connections must correspond to at least the protection class in
accordance with the name plate and/or required country-specific protec-
tion class.

WARNING
Contact with rotating or moving parts!
Entanglement of clothing or body parts can lead to crushing or even loss of
limbs.
Maintain an adequate distance to rotating and moving parts, for example
traction sheave, ropes.
Wear tight-fitting clothing.
Make sure you assume a firm stance.

▪ The drive may only be operated in a closed machine room or secured

shaft.
▪ The machine may only be operated with the cover and rope guard fitted to
the traction sheave.
▪ The drive is not suitable for operation in explosive or aggressive atmo-
spheres.
▪ On entering the machine room, adequate safety clearance to all rotating
parts is to be maintained.
▪ In the event of improper use of the machine, there is a risk of personal in-
jury or to the life of the user or third parties, or impairment on the as-
sembly or other assets can arise. Malfunctions that can adversely affect
safety must be rectified immediately.
▪ It must be ensured that a fault generated by the encoder, the brake or the
brake control system is detected by the elevator control system or fre-
quency inverter. The control system must immediately place the elevator
in a safe state.
▪ The elevator installation must ensure that emergency braking by the
mechanical brake system takes place in the following cases:
– Uncontrolled movement out of the stopping zone

TK Elevator
BA, TW45 | 6231003860 | 03/2023
 Safety
10 Warranty and liability

– Failure of the inverter (due to short circuit with triggering of the fuse)
▪ The elevator installation must be fitted with a safety device complying
with EN81 or A17 that detects exiting the elevator car with the door
opened and initiates suitable measures.

2.3 Warranty and liability

The "General Terms of Sale and Delivery" of TK Aufzugswerke GmbH apply.
Warranty and liability claims in the event of personal injury and material dam-
age shall be excluded if they arise due to at least one of the following causes:
▪ Improper use that is not in line with the intended purpose of the product
▪ Incorrect installation, commissioning, operation and maintenance of the
product
▪ Operation of the product with defective or inoperative safety and/or pro-
tection devices
▪ Non-observance of the instructions in the operating manual with regard to
transport, storage, installation, commissioning, operation and mainten-
ance
▪ Structural modification to the product without agreement or approval
▪ Modification to product features without agreement or approval
▪ Inadequate monitoring of parts that are subject to wear
▪ Repairs that are carried out improperly
▪ Cases of catastrophe due to third-party interference or force majeure
▪ Use of non-approved auxiliary materials and operating fluids

2.3.1 Structural modification of the product

The product is configured in the factory and delivered ready for operation.
If changes are made to the product, the entire warranty of TK Aufzugswerke
GmbH shall become null and void.

2.3.2 Use in line with intended use

The product has been constructed using state-of-the-art technology and in
line with the recognised technical safety regulations. It may only be used in
accordance with its intended use and when the technical safety devices are
free from defects. Any other or additional form of use shall be regarded as
non-compliant with the intended use. TK Aufzugswerke GmbH shall not be li-
able for any damage arising from such use and any damage arising due to op-
erator errors.
In order to comply with the intended use of the product:
▪ Use the product as a Drive of elevators only
▪ Read and comply with the document, in particular the chapter entitled
"Safety", together with the warnings and all other applicable documents
▪ Comply with the commissioning instructions, the installation description
as well as the required inspection and maintenance work

TK Elevator
BA, TW45 | 6231003860 | 03/2023
Safety
10 rules for health and safety at work 11

2.4 10 rules for health and safety at work

The international rules for occupational health and safety can also be found
on our internet platform ELI for download at: https://eli.tkelevator.com/sup-
port/occupational-safety-health

TK Elevator
BA, TW45 | 6231003860 | 03/2023
 Safety
12 Personal protective equipment

2.5 Personal protective equipment

Danger Cause Risks Remedy Equipment

Safety har-
▪ Unprotected shaft Falling
ness

▪ WARNING!
Do not walk underneath suspended
loads
Head protec-
▪ Falling tools Head injury
tion
▪ Transport of heavy loads
▪ Sharp-pointed objects
▪ WARNING!
Do not walk underneath suspended Danger of crushing in the
loads foot area Foot protec-
▪ Falling tools Cut or stab injury in the tion
▪ Transport of heavy loads foot area
▪ Sharp-pointed objects

▪ Sharp objects Danger of crushing in the

▪ Mechanical parts hand area Protective
▪ Sharp-pointed objects Stab injury in the hand area gloves
▪ Caustic substances Acid/alkali burns

Ear protec-
▪ Severe noise pollution Noise damage
tion

▪ Flying parts
▪ Flying particles Eye injury Protective
▪ Laser beams Loss of sight/blinding goggles
▪ Emissions of optical rays

Enable
▪ Electrical voltage Electric shock source of en-
ergy

TK Elevator
BA, TW45 | 6231003860 | 03/2023
Description
Standards and legal requirements 13

3 Description
3.1 Standards and legal requirements
The product complies with the following regulations:
▪ DIN EN 81-20:2020-06
▪ DIN EN 81-50:2020-06
▪ DIN EN 81-77:2019-01

i For operation in line with standards, the elevator installation must comply with
each standard.

3.2 Product Group TW Machines

The designation of this series (successor generation of W series) is composed
of the combination of TK Elevator, Wormgear (TW) and a figure for the main
performance point (e.g. Q = 1600 kg → 160) of the machine, as well as an in-
dicator of the generation (e.g. "B").
As part of further technical development, these machines are designed com-
pletely with low-friction rolling bearings.
The use of a synthetic gear oil (polyalkylene glycol with additives) not only in-
creases the power density and the gear efficiency, but also extends the oil
change intervals.

3.3 Product
The TW45C machine (TK Elevator, Wormgear / Q = 450 kg / generation C) is
used within the framework of the TW model series (machines with worm
gears, anti-friction bearings, lubrication with synthetic gear oil) for traction el-
evators in the lower range of performance.
The TW45C has been available since May 2011 and it differs from the previous
version TW45B in that there are modified anti-friction bearings with optimised
sealing (stroke unit on worm shaft).
The TW45C machine, conceived for systems with rated load 450 kg at 1.0 /
1.25 m/s, consists of a worm gear with integrated service brake, overhung
traction sheave, flange-connected three-phase motor in IMB5/V1 structural
shape as well as the optionally possible emergency brake, NBS.
The corresponding production, assembly and assignment of the components
means that the versions of the machine described below are possible:
▪ Vertical upright motor position; traction sheave position on left; with /
without emergency brake system, NBS – for machine location in the ma-
chine room.
▪ Horizontal motor position; traction sheave position on left / on right; with /
without emergency brake system, NBS – for machine location in the ma-
chine room.

TK Elevator
BA, TW45 | 6231003860 | 03/2023
 Description
14 Product

▪ ISIS1 version: Horizontal motor position; traction sheave position on left /

right, with emergency brake system, NBS – for location in the shaft pit.
The machine is exclusively available with frequency-controlled motors (V3F).

TW45C in horizontal version for installation in the machine room

Fig. 1 ATR_2_21_0027_0

Item Designation Item Designation

Tension disc on traction sheave
1 Rope guard 2
shaft with screwed connection
3 Traction sheave 4 Gear
5 Transport eyebolt 6 Brake release lever
Motor terminal box, including in-
7 termediate terminal connection 8 Service brake
for brake
9 Encoder 10 Handwinding wheel
11 Motor

Installation in the machine room / vertical motor position IMV1

Fig. 2 ATR_2_21_0028_0

TK Elevator
BA, TW45 | 6231003860 | 03/2023
Description
Product 15

Item Designation Item Designation

Driving gear (vertical motor pos- Traction sheave (D440 / D520 /
1 2
ition) D590)
Service brake Mayr
Motor (version with terminal box
RSZ125-2x50 Nm, including
3 for connection of the service 4
mounted lever for manual re-
brake)
lease
5 Encoder 6 Handwinding wheel (D270)
7 Rope guard (adjustable) 8 Oil drain (3/4")
Oil filling hole and ventilation Oil level monitoring (gauge
9 10
(R3/4") glass)
Motor connection

Traction sheave mounting (ten- (M16x1.5 / M25x1.5)

11 sion disc with screwed connec- 12 Brake connection
tion) (2x M16x1.5)

Mounting surface for machine

13 Transport eyebolts 14
base frame

TK Elevator
BA, TW45 | 6231003860 | 03/2023
 Description
16 Product

Installation in the machine room / horizontal motor position

IMB5

Fig. 3 ATR_2_21_0029_0

Item Designation Item Designation

Driving gear (horizontal motor Traction sheave (D440 / D520 /
1 2
position) D590)

Motor Service brake Mayr

RSZ125-2x50 Nm, including
3 (version with terminal box for 4
mounted lever for manual re-
connection of the service brake) lease
5 Actual-value sensor 6 Handwinding wheel (D270)
7 Rope guard (adjustable) 8 Oil drain (R3/4")
Oil filling hole and ventilation Oil level monitoring (gauge
9 10
(R3/4") glass)
Traction sheave mounting (ten- Motor connection (M16x1.5 /
11 sion disc with screwed connec- 12 M25x1.5)
tion) Brake connection (2 M16x1.5)
Mounting surface for machine
13 Transport eyebolt 14
base frame

TK Elevator
BA, TW45 | 6231003860 | 03/2023
Description
Product 17

Installation in the machine room / with emergency brake system,

NBS (shown with machine in horizontal motor position)

Fig. 4 ATR_2_21_0030_0

Item Designation Item Designation

Disc brake - emergency brake
1 2 Cover plate for brake
system, NBS
Socket wrench for manual re- Screws for manual release
3 4
lease (screw head marked in red)
Brake test switch with connec-
5 6 Connection line, brake voltage
tion line
7 Protective cover for brake

TK Elevator
BA, TW45 | 6231003860 | 03/2023
 Description
18 Product

Machine room with horizontal rope departure direction (shown is

the left traction sheave position / horizontal motor position)

Fig. 5 ATR_2_12_0105_0

The machine contains only the components for the rope guard of the top rope
line. To assist installation of these components, the bearing bracket on the
traction sheave side has been fitted at the plant rotated by 60°. The hori-
zontal rope departure direction is possible in both directions (opposing the
motor and/or towards the motor with horizontal motor position). With a ver-
tical motor position, both horizontal directions are also possible. The top rope
guard can be adjusted +/- 15° in relation to the horizontal. The additional com-
ponents required for the rope guard of the bottom rope line and/or in the area
between the rope entry and departure points required in accordance with
EN81-1:1998 and/or EN81-20/5.5.7 are not included in the scope of supply of
the machine and must be fitted on the machine base frame depending on the
order.

Machine room with earthquake safeguard complying with

EN81-77 (shown in the left traction sheave position / vertical
motor position and earthquake safeguard complying with
EN81-77)

Fig. 6 ATR_2_12_0106_0

TK Elevator
BA, TW45 | 6231003860 | 03/2023
Description
Product 19

Item Designation Item Designation

Traction sheave (D440 / D520 / Earthquake safeguard comply-
1 2
D590) ing with EN81-77

Special version SA1 (modified mounting of the machine,

including compensation washers)
M16-10.9 - 190 NM

Fig. 7 ATR_2_12_0151_1

ISIS1 version (MRL – machine in the shaft pit)

Fig. 8 ATR_2_12_0149_0

The machine has a "horizontal" motor position.

The position of the motor terminal box is at the side opposite the traction
sheave.
In general, the ISIS1 version of the machine has the NBS emergency brake
system.
The traction sheave shown in the diagram is not included in the scope of sup-
ply. It is made available by TKE-NA.
The components for the rope guard and the fastening elements for the ma-
chine on the machine base frame are also made available by TKE-NA.
The connection lines of the service and emergency brakes are routed through
the enlarged motor terminal box and routed by means of conduits into a mo-
tor interface box (MIB).
The motors made by EMOD are voltage interchangeable 230 / 460 V and
have no handwinding wheel. The motors have CSA certification.

TK Elevator
BA, TW45 | 6231003860 | 03/2023
 Description
20 Product

Deviating from the standard version, the versions of the service brake and
emergency brake are operated with a lower voltage of 110 / 55 V DC. Both
brakes have CSA certification.
The service brake with 2x50 Nm is regarded as a 100 Nm brake (ASME A17.1)
for this use case.
The encoder used is a Wachendorff WDG100-2x2048 TTL with a 3 m line
length.

3.3.1 Machine base frame

Various machine base frame versions are possible. Consult the general ar-
rangement drawings.
The machine base frames with / without rope pulley described below are in-
tended for installation of the machine in the machine room above the shaft.
The machine base frame without rope pulley consists of three plated-edge
longitudinal brackets with two welded face plates. The hole pattern in the ma-
chine base frame permits a shift of the machine on the machine base frame in
the hole distance 40/50 mm.
The machine base frame with rope pulley consists of the machine base frame
without rope pulley as an upper frame part and bolted-on supports for the
rope pulley bearings and insulation elements.
With this machine base frame, there is the possibility for a right-hand or left-
hand configuration of the rope pulley position with the corresponding installa-
tion of the supports.

Setup
As a rule, the machine base frame is set up on insulation elements (rubber
blocks) either on a machine base frame support (steel support) or directly on
the machine room floor.
The components for the rope guard in accordance with EN81-1/9.7 and
EN81-20/5.5.7 are part of the machine.

Weight of machine base frame

Version of rope pulley [mm] Weight, including rope pulley [kg]
D360 140
D450 170
Weight of machine base frame without rope pulley: 50 kg

ASY TW45B O SR machine base frame

The TW45B O SR machine base frame (shown with machine in vertical motor
position and traction sheave position on left) in version without rope pulley is
used for:
▪ Installations with rope suspension 1:1 and direct rope departure with a rope
distance elevator car - counterweight ASL ≤ (DT + 100) mm with traction
sheave diameter 520 or 590 mm
▪ Installations with rope suspension 2:1 and traction sheave diameters 440,
520, or 590 mm

TK Elevator
BA, TW45 | 6231003860 | 03/2023
Description
Product 21

Fig. 9 ATR_2_21_0039_0

Item Designation Item Designation

TW45B O SR machine base
1 TW45C machine 2
frame
Mounting parts for machine
3 Insulation elements 4
base frame

ASY TW45B M SR machine base frame

The TW45B M SR machine base frame (pictured is the rope pulley in the
right-hand arrangement with the machine in horizontal motor position and
left-hand traction sheave position, including emergency brake, NBS) in the
version with rope pulley depending on the rope pulley position in left-hand or
right-hand arrangement for use on:
▪ Installations with rope suspension 1:1 and rope distance elevator car -
counterweight
ASL = 608 - 833 mm and traction sheave diameter 440 or 520 mm
▪ The rope pulleys that are used are the versions D360-7xdia.8 (traction
sheave with 5/7xdia.8), dia.450-7xdia.10/11 mm (traction sheave with
5xdia.10/11) or dia.450-8xdia.10/11 mm (traction sheave with 6xdia.10/11).
The rope pulleys (versions, see product description of rope pulleys) are
designed with maintenance-free roller bearings.

Fig. 10 ATR_2_21_0040_0

Item Designation Item Designation

TW45B M SR machine base
1 TW45C machine 2
frame
Mounting parts for machine
3 Insulation elements 4
base frame

TK Elevator
BA, TW45 | 6231003860 | 03/2023
 Description
22 Product

Mounting parts for machine on TW45B machine base frame

A set of screwed connection elements (M16 - 8.8) is available for mounting
the TW45C machine on the TW45B O SR / M SR machine base frames.
A modified mounting SA1 (4 x M16-10.9 – 190 Nm) is required for TW45C ma-
chine use cases with horizontal or vertical upward rope departure - except for
the housing with flange mounting.

Version with earthquake safeguard complying with EN81-77

Optional components are available for the TW45B O SR and TW45B M SR
base frames; these meet the requirements for protection devices complying
with EN81-77.

Fig. 11 ATR_2_12_0155_0

Ite Designation Ite Designation

m m
Rope guard complying with
1 TW45C machine, vertical 2
EN81-77 for traction sheave
Rope holder complying with
TW45B M SR machine base
3 4 EN81-77 for rope pulley diameter
frame
D450
Shift protection device comply-
5
ing with EN81-77
The safeguard measures are only suitable for machine base frames with loca-
tions in the machine room.
The protection device consists of a modified rope guard for rope pulleys of
diameter D360 or D450 which prevent the ropes departing from the grooves.

Fig. 12 ATR_2_12_0156_0

TK Elevator
BA, TW45 | 6231003860 | 03/2023
Description
Product 23

Ite Designation Ite Designation

m m
Rope holder complying with
TW45B M SR machine base
1 2 EN81-77 for rope pulley diameter
frame
D360
Rope holder complying with
3 Rope pulley diameter D360 4 EN81-77 for rope pulley diameter
D450
5 Rope pulley diameter D450
The safeguard measures also consist of shift protection devices that prevent
the machine from changing its position.

Fig. 13 ATR_2_12_0157_0

Item Designation Item Designation

TW45B M SR machine base Shift protection device comply-
1 2
frame ing with EN81-77

3.3.2 Motor versions

Frequency-controlled three-phase motors made by CEG and EMOD are used
(for ISIS1). The mechanical layout (design IMB5/V1, flange A250, AS/BS shaft
ends, encoder mounting etc.) is executed in accordance with building code BV
6531- 07 Sheet 1 and/or the dimension sheets of CEG and EMOD.
In extension of the building code, the motors are modified and receive a larger
terminal box with the possibility to connect the connection lines of the opera-
tional brake (type Mayr RSZ 125) to a terminal block. For connection of the
brake (coil and microswitch) on the installation side, 2 M16x1.5 cable glands
are available on the motor terminal box.
Related to the motor shaft, mounting and thus the location of the motor con-
nection box is possible under 4x90°.
In the case of the ISIS1 version, the position of the motor terminal box is gen-
erally at the side opposite the traction sheave.
The specified electrical data apply to the following site conditions:
▪ Max. altitude 1000 m amsl
▪ Max. temperature + 40°C at max. 50% air humidity
▪ Max. relative air humidity 70% at 20°C
If the conditions stated above are exceeded, the deratings in accordance with
VDE0530 apply.
The standard version of the encoders (for description and technical data, see
product catalogue for elevator motors) include a 10-metre long connection
cable, including connectors (types 1024/4096 TTL) for connection to TK El-
evator frequency inverters and/or free cable ends with wire end ferrules (type
1024 HTL and type 1024 sine/cosine). An encoder with 2048 TTL and 3 m
connection line is used for the ISIS1 (MRL).

TK Elevator
BA, TW45 | 6231003860 | 03/2023
 Description
24 Product

3.3.3 Special versions

The following optional versions are possible:
▪ Emergency brake, NBS (only with machine location in the machine room
or ISIS1)
▪ Actual-value sensor in accordance with Chap. 4.1.3 P. 29
▪ Earthquake safeguard complying with EN81-77 (only with machine loca-
tion in the
machine room; not with horizontal rope departure direction)
▪ SA1 - modified machine fastening (including compensating sheaves) for
horizontal or vertical upward force resulting from rope pull
▪ Horizontal rope departure direction; other information Product
▪ Version for ISIS1 (description Product)
Other special versions or options are currently not available.

3.3.4 Standard version for machine in the machine room

The standard version of the machine TW45C comprises the following com-
ponents:
▪ Driving gear (incl. oil filling; vertical/horizontal motor position; traction
sheave position - left/right)
▪ Gear ratios 46:1, 32:1, 41:2, 40:3 or 32:3 (32:3 only for ISIS1)
▪ Service brake type Mayr RSZ125-2x50 Nm including permanently moun-
ted brake release lever and brake monitoring (microswitch)
▪ Motor in version EME (CEG) MT132 (5.2 kW) or EME (CEG) MT132 (7
kW); mounting with terminal box location Product and as standard; motor
versions with intermediate terminal connection for connection lines of the
service brake
▪ Encoder; version WDG100-1024 TTL as standard
▪ Handwinding wheel, diameter 270
▪ Traction sheave dia. 440, dia. 520 or dia. 590 as standard
▪ Components for the rope guard; standardised for traction sheave dia. ,
440, 520 and dia. 590
▪ Blocking clamp

3.3.5 Version with emergency brake, NBS

The optional version of the emergency brake (NBS) meets the requirements
for the protection device that prevents overspeed in the upward-moving elev-
ator car in accordance with EN81-1:1998 / 9.10 and/or EN81-20/5.6.6 and un-
intended elevator car movements in accordance with EN81-1:2010-06 / 9.11
(EN81-1/A3) and/or EN81-20/5.6.7.
In the ISIS1 version, the NBS emergency brake also meets the requirements in
accordance with ASME A17.1.
Alongside the service brake, an additional braking device is fitted on the drive
shaft, consisting of the components:
▪ Type-approved electromagnetic disc brake in accordance with
Chap. 4.1.6 P. 32

TK Elevator
BA, TW45 | 6231003860 | 03/2023
Description
Product 25

▪ Driving gear in emergency brake NBS version (bearing bracket NBS, brake
flange NBS for fitting the brake)
▪ Traction sheave / worm wheel shaft NBS (including components for seal-
ing)
The braking device is located on the machine side opposite the traction
sheave and directly affects the traction sheave shaft.
A certificate with respect to the calculation of the traction sheave shaft for
the machine TW45C with emergency brake system (NBS) shall be enclosed
with the technical documentation.
The emergency brake is activated via a separate control unit including ter-
minal box and connecting lines as well as an additional safety switch at the
overspeed governor (TK Aufzugswerke GmbH) to activate the facility in the
event of overspeed (not for ISIS1 version).
For the version in the machine room, the emergency brake is released manu-
ally (e.g. emergency rescue in the event of a power failure) via screws that are
screwed into the brake in the event of triggering, thus releasing the brake/
armature base plate of the disc brake. During normal operation, the screws
and a socket wrench are kept in the guard plate of the brake.
For installation of the manual release screw, a minimum distance of 100 mm
is to be set between the emergency brake and the adjoining wall of the ma-
chine room or similar.
Later fitting of the emergency brake, NBS, on existing machines is not pos-
sible.

3.3.6 Version with earthquake safeguard complying with

EN81-77
The optional version of the rope guard complying with EN81-77 enables com-
pliance with the requirements for protection devices in earthquake regions up
to earthquake category 1 as standard.
The rope guard fitted as standard is replaced with the modified rope guard
which, in the event of an earthquake, prevents the ropes from leaving the
groove of the traction sheave. Attention should be paid to ensuring that the
rope guard is installed in accordance with the installation instructions.
The rope guard complying with EN81-77 is standardised for the traction
sheave diameters 440 / 520 / 590. The rope guard is designed in such a way
that all standard gaps between the ropes on the rope departure can be
covered with the TW45B O SR and TW45B M SR base frames.

3.3.7 Version for machine location in the shaft pit for ISIS1
This version is intended for TKE-NA. The machine is located in the shaft pit
with upward vertical rope pull and is intended for a range of performance
from 2100 lbs/100 fpm to 3000 lbs/200 fpm, with traction sheave 10.5 in
(D267 mm) and rope attachment 2:1 in each case.
As gear ratios, the versions 40:3 and 32:3 are intended. The versions EMOD
5.5 / 7.5 and 11 kW in voltage interchangeable version 230 / 460 V are de-
ployed as motors.

TK Elevator
BA, TW45 | 6231003860 | 03/2023
 Description
26 Combination of versions / options

3.4 Combination of versions / options

Machine room
Horizontal

EN81-77
Combination

Vertical
E11.0

ISIS1
C7.0
C5.2
40:3

E5.5

NBS
E7.5
32:3

440

590
46:1

520
41:2
32:1

SA1
46:1
32:1 O
41:2 O O
40:3 O O O
32:3 O O O O
C5.2 X X X X O
C7.0 X X X X O O
E5.5 O O O X X O O
E7.5 O O O X X O O O
E11.0 O O O X X O O O O
Machine room X X X X O X X O O O
Horizontal X X X X X X X X X X X
Vertical X X X X O X X O O O X O
440 X X X X O X X O O O X X X
520 X X X X O X X O O O X X X O
590 X X X X O X X O O O X X X O O
NBS X X X X X X X X X X X X X X X X
EN81-77 X X X X O X X O O O X X X X X X X
ISIS1 O O O X X O O X X X O X O O O O X O
SA1 X X X X O X X O O O X X X X X X X O O
Tab. 1 ATR_1_21_0047_0

X Combination possible
O Combination not possible or not intended
46:1 / 32:1 / 41:2 / 40 :3 / 32:3 versions - gear ratio
C 5.2 / 7.0 kW versions - motor CEG / E 5.5 / 7.5 /. 11.0 kW versions - motor EMOD
TWR machine location - machine room
Horizontal / vertical versions - motor position
440 / 520 / 590 traction sheave versions
NBS Version with emergency brake-NBS
EN81-77 Version with earthquake protection in accordance with EN81-77
ISIS1 Delivery version for ISIS1 / SA1 version with modified fastening

TK Elevator
BA, TW45 | 6231003860 | 03/2023
Technology
Mechanical data 27

4 Technology
4.1 Mechanical data

4.1.1 Gear unit

Single-stage worm gear with:
▪ Housing in monoblock design (EN-GJL 250) with separate AS and BS
bearing brackets
▪ Two housing variants in the respective version adapted for the mounting
surface to machine base frame and motor position:
- Vertical motor position (NBS emergency brake possible)
- Horizontal motor position (NBS emergency brake possible)
▪ Motor flange (construction size A250) integrated on housing
▪ Worm shaft made of case-hardened steel (16MnCrS5); optimised roller
bearings via stroke unit with life-time grease lubrication and optimised
seal system
▪ Worm wheel made of centrifugally cast bronze (CuSn12Ni-C-GZ) with
screw-connected hub
▪ Traction sheave shaft made of tempering steel (C60R+N and/or
42CrMo4+QT), roller bearings with oil-bath lubrication
▪ Contact pattern position of gear teeth adjustable; backlash not adjustable
▪ Components for the rope guard suitable for traction sheaves dia. / 440 /
520 and 590 in accordance with EN81-1:1998 and/or EN81-20/5.5.7 (not
generally with horizontal rope departure direction).
▪ With vertical motor position, gear teeth run under oil; with horizontal mo-
tor position, with transport oil from oil sump via worm wheel gear teeth
▪ Oil level monitoring via gauge glass; oil drain (R3/4"); casing ventilation
▪ Machine type plate

Version Unit TW45C

Axle distance [mm] 120
Gear ratio 40:3/41:2/32:1/46:1/32:3
Oil filling, motor po-
[L] 4.0
sition
Synthetic gear oil (polyalkylene glycol with ad-
Oil grade
ditives)
Designation SM1
Backlash [°] 0.03-0.07
Weight [kg] approx. 105
Tab. 2 ATR_1_21_0005_0

TK Elevator
BA, TW45 | 6231003860 | 03/2023
 Technology
28 Mechanical data

4.1.2 Brake
Version for deployment in the machine room and ISIS1 (MRL)
Designation Unit Technical data
Manufacturer Chr. Mayr GmbH
Type ROBA-stop RSZ125
Version Machine room ISIS1 (MRL)
Braking torque [Nm] 2 x 50 100 (2 x 50)
Braking torque setting Not possible
2-surface disc brake (2 mechanical brake circuits with a joint electro-
Design
magnetic circuit for release)
Brake linings Asbestos-free
Brake disc diameter [mm] 130
Air gap [mm] 0.5 +0.25
Air gap setting Not possible
Electrical release 1 magnetic clamp with armature base plate
Operating voltage
Overexitation / holding [VDC] 180 / 90 110 / 55
current
Operating current
Overexitation / holding [A] 1.68 / 0.84 2.58 / 1.29
current
Performance data
Overexitation / holding [W] 303 / 76 284 / 71
current
Monitoring devices Release monitoring (microswitch)
Manual release lever (permanently
Manual release without
mounted) 1)
1 m (with end sleeves; connection 3 m (with end sleeves; connection
Connection lines, coil and
[m] lines have intermediate clamping lines are routed through the motor
microswitch
in the motor terminal box) terminal box)
Type of protection IP54
Weight [kg] approx. 11
CSA LR 34805
Type approval code without (not required)
Tab. 3 ATR_1_21_0023_0

1)
Manual release of both brake circuits; single-circuit test by means of pluggable test gauges.

In general, this brake is made with brake monitoring (microswitch).

This brake is also used for the ISIS1 version with the machine in the shaft pit,
but in an adapted version with altered voltage and without a manual release
lever. With ASME A17.1, the brake is regarded as 100 Nm (2x50 Nm).

TK Elevator
BA, TW45 | 6231003860 | 03/2023
Technology
Mechanical data 29

Version with NBS emergency brake

Designation Unit Technical data
Manufacturer Chr. Mayr GmbH
Type Mayr RSO500/1200 Nm
Version Machine room ISIS1 (MRL)
Braking torque [Nm] 1200
Braking torque setting Not possible
Design 4-surface disc brake
Version of brake linings Asbestos-free
Brake disc diameter [mm] 213
Air gap [mm] 0.6
Air gap setting / stroke Not possible
Electrical release 1 magnetic clamp with armature base plate
Operating voltage
[VDC] 207 / 104 110 / 55
Overexitation / holding voltage
Operating current
[A] 1.7 / 0.85 3.28 / 1.64
Overexitation / holding current
Performance data
[W] 353 / 88 361 / 90
Overexitation / holding power
Monitoring devices Release monitoring (microswitch)
Manual emergency release 2 x M10 screws
approx. 4 m (with end sleeves;
Connection lines, connection lines are routed
approx. 1 m (with end sleeves)
coil and microswitch through the motor terminal
box)
Type of protection IP54
Weight [kg] approx. 50
Type approval code EU-BD 762 2) and/or ABV 762/2 3)
Type approval code EU-BD 762 2) and/or ESV 762/2 3)
Times: t10 / t50 / t90 1) [ms] 55 / 90 / 180
Certificate for traction sheave
shaft TW45C-RSO500/1200 Nm
Test number:
CSA LR 34805
Tab. 4 ATR_1_21_0040_0

1) DC - direct current cut-off (emergency stop).

2) Complying with EN81-20/50.
3) Complying with EN81-1:1998+A3:2009.

4.1.3 Encoder
The following hollow shaft encoders are available:

TK Elevator
BA, TW45 | 6231003860 | 03/2023
 Technology
30 Mechanical data

Number of pulses Version Connection

2x1024 TTL Line and connector hard-wired
2x4024 TTL Line and connector hard-wired
Line stripped of insulation and wire
2x2048 TTL
end sleeves attached
Tab. 5 ATR_1_21_0072_0

4.1.4 Traction sheave

The one-part traction sheaves are fastened overhung on the traction sheave
shaft using a cone (1:15) and a mounting plate, including 3 screws (M16-8.8
microencapsulated with locking washer).

Designation Unit Technical data

Diameter - DT [mm] 440 520 590
Rim width - B [mm] 115
9 x 8 (8 x 8)
8 x 9 (7 x 9)
Max. number of
7 x 10 (6 x 10)
grooves - z x d 2)
6 x 11
6 x 12 (5 x 12)
Groove type Seat/vee groove 1)
Groove angle [°] Depends on project specs 1)
Tab. 6 ATR_1_21_0011_0

1)
Version in accordance with product description, groove profiles with hardened groove flanks
(min. 50 HRc).
2)
With minimum groove clearance - RAmin - in accordance with product description for groove
profiles for seat grooves (for vee grooves, if deviating).
TKE-NA provides a D267 mm traction sheave for the ISIS1 (MRL) version (not in the scope of
supply of TK Aufzugswerke GmbH).

4.1.5 Performance chart

Applications in the standard
r vn n1 DT i vn1 Q´max F´max x
630 50
0.50 1000 440 0.50 800
675 45
550 850 50
1250 440
630 800 45
500 50
0.63 1070 520 0.63 850
550 45
1:1 46:1
450 50
940 590
500 45
450 50
1600 440 800
500 45
0.80 0.80
450 50
1350 520
500 45

TK Elevator
BA, TW45 | 6231003860 | 03/2023
Technology
Mechanical data 31

r vn n1 DT i vn1 Q´max F´max x

400 50
1190 590
450 45
630 50
1100 440
675 45
550 850 50
1390 440
630 800 45
1.00 1.00 500 50
1180 520 850
550 45
32:1
1040 590 450 850 45/50
475 900 50
1740 440
525 850 45
1.25 1.25 425 50
1470 520 900
475 45
1300 590 400 800 45/50
350 700 50
1650 590 32:1
375 800 45
400 50
1420 440 1000
1.60 1.60 450 45
41:2
1200 520 400 900 45
1060 590 375 850 45
930 440 40:3 450 800 45/50
1600 440 1000
46:1
0.40 1350 520 0.40 900
1110 440 1300
1390 440 1150 1600 50
0.50 0.50
1180 520 32:1 1050
1750 440 1000
1470 520 900
0.63 1300 590 32:1 0.63 850 1600 50
1050 1500 50
1120 440 41:2
1200 1400 45
2:1
950 50
1420 440 1350
1050 45
850 50
1210 520 1350
0.80 0.80 950 45
750 1500 50
1060 590 41:2
850 1400 45
930 440 40:3 1050 1500
50
825 1300
1780 440
1.00 41:2 1.00 900 1400 45
1510 520 750 1250 50

TK Elevator
BA, TW45 | 6231003860 | 03/2023
 Technology
32 Mechanical data

r vn n1 DT i vn1 Q´max F´max x

825 1300 45
675 50
1330 590 41:2 1300
750 45
900 50
1160 440 40:3 1500
1000 45
Tab. 7 ATR_1_21_0048_0

r - Rope suspension
vn fpm (m/s) rated speed
n1 (rpm) Motor speed
DT in (mm) Diameter of traction sheave
i - Gear ratio
Q´max lbs (kg) Rated load (maximum)
F´max lbs (kg) Mass of car (maximum at Q´max)
x (%) Counterweight compensation

Applications in the ISIS1

r vn n1 DT i Q´max F´max x
100 10.5
970 40:3
(0.508) (267)
150 10.5 3000 3500
2:1 1455 40:3 45
(0.762) (267) (1361) (1588)
200 10.5
1555 32:3
(1,016) (267)
Tab. 8 ATR_1_21_0050_0

r - Rope suspension
vn fpm (m/s) rated speed
n1 (rpm) Motor speed
DT in (mm) Diameter of traction sheave
i - Gear ratio
Q´max lbs (kg) Rated load (maximum)
F´max lbs (kg) Mass of car (maximum at Q´max)
x (%) Counterweight compensation

All specified performance data in Chap. 4.1.5 P. 30 apply to the following

application conditions:
▪ Operating data max. 180 c/h at 50% duty cycle
▪ Ambient temperature + 5°C to + 40°C
For types of performance not shown in the chart or deviating installation data,
there is the possibility to use a calculation program (e.g. TK Liftdesigner) to
check the operational safety of the machine.
The machines are conceived for a service life of at least 15 years and/or
20,000 hours of operation.

4.1.6 Motor versions

Standard versions of motors
Designation Unit Technical data
Manufacturer EME (CEG)
Type MT132STD MT132STD

TK Elevator
BA, TW45 | 6231003860 | 03/2023
Technology
Mechanical data 33

Designation Unit Technical data

20197S 20193S
Motor version
C5.2 400 C7.0 400
TKAW designation
Voltage/frequency [V/Hz] 340/42
S5 operating data 180 c/h / 50% DC
Speed range [rpm] 1000-1249 1250-1800 1000-1249 1250-1800
Power output [kW] 4.2-5.2 5.2 5.6-7.0 7.0
Torque [Nm] 40 40-28 54 54-37
Rated current [A] 12.5 16.5
Permitted starting
[Nm] 70 70-63 88 88-79
torque
Permitted starting cur-
[A] 20 25
rent
Effective voltage [V] 340 340
cos ϕ 0.87 0.88
Efficiency 0.82 0.82
Design IMB5/V1
Type of protection IP55
Ventilation Internal ventilator
1)
Handwinding wheel [mm] D270 (plastic)
kproj. [mm] 485
Weight [kg] 50 60
Actual-value sensor WDG100-38-1024/4096 TTL
Tab. 9 ATR_1_21_0034_0

Motors in voltage interchangeable version with CSA for ISIS1

Designation Unit Technical data
Manufacturer EMOD
Type 132S/4 132M/4 132M/4a
Motor version
E5.5 230/460 E7.5 230/460 E11.0 230/460
TKAW designation
S5 operating data 180 c/h / 50% DC
Rated speed [rpm] 970 1460 1555 970 1460 1555 970 1460 1555
Nominal frequency [Hz] 34.0 50.4 53.7 34.0 50.7 53.7 34.0 50.7 54.0
156// 156// 156//
Rated voltage 1) [V] 230//460 230//460 230//460
312 312 312
Rated power [kW] 3.7 5.5 5.5 5.0 7.5 7.5 7.4 11 11
Rated torque [Nm] 36.4 36.0 33.8 49.2 49.1 46.1 72.8 71.9 67.5
20.4// 27.2// 39.0//
Rated current [A] 21.0//10.5 28.0//14.0 41.0//20.5
10.2 13.6 19.5
max. starting torque [Nm] 45 100 140
Max. starting current [A] 42//21 56//28 86//43

TK Elevator
BA, TW45 | 6231003860 | 03/2023
 Technology
34 Mechanical data

Designation Unit Technical data

cos ϕ 0.81 0.83 0.80
Efficiency 86 85 87
Design IMB5/V1
Type of protection IP55
CSA LR 34805
Ventilation Internal ventilator
Handwinding wheel [mm] without
kproj. [mm] 437 475 503
Weight [kg] 57 70 75
Actual-value sensor WDG100-38-2048 TTL
Tab. 10 ATR_1_21_0046_0

1)
Voltage interchangeable YY//Y

The specified electrical data apply to the following site conditions:

▪ Maximum altitude 1000 m amsl
▪ Max. temperature + 40 °C at max. 50% air humidity
▪ Max. relative air humidity 70% at 20°C
If the conditions stated above are exceeded, the deratings in accordance with
VDE0530 apply.
Please refer to the product catalogue Product catalogue for elevator motors
for detailed technical data for the motors and encoders.

4.1.7 Load data - traction sheave shaft

The load value Ftzul listed below is the limit value of the permitted radial stress
for the traction sheave shaft calculated from the overall mass present on the
installation.
The overall mass of the installation is determined and the load is checked as
part of the calculation program TK LiftDesigner.
▪ Radial shaft load for n2 = n1 / i ≤ 50 rpm: Ftzul ≤ 30 kN
▪ Radial shaft load for n2 = n1 / i > 50 rpm: Ftzul ≤ 26 kN
▪ Radial shaft load for ISIS1 version: Ftzul ≤ 27.9 kN

4.1.8 Load data for upward horizontal / vertical rope pull

direction
For the configuration of the machine with the standard version of the traction
sheave shaft or in the version for the emergency brake system, NBS, there are
restrictions due to the housing strength for the permitted load Ftzul-stat de-
pending on the installation data for the upward horizontal or vertical rope pull
direction.

TW45C with vertical motor position

▪ Horizontal rope pull: Ftzul-stat = 76 kN ≤ Ftstat-max
▪ Upward vertical rope pull: Ftzul-stat = 56 kN ≤ Ftstat-max

TK Elevator
BA, TW45 | 6231003860 | 03/2023
Technology
Mechanical data 35

TW45C with horizontal motor position

▪ Horizontal rope pull: Ftzul-stat = 94 kN ≤ Ftstat-max
▪ Upward vertical rope pull: Ftzul-stat = 70 kN ≤ Ftstat-max
The load Ftstat-max present for the static overload case is determined via the TK-
LiftDesigner, etc.
The values for upward horizontal and/or vertical rope pull directions can be
used up to +/- 45° respectively for rope pull directions between upward hori-
zontal and vertical.

45°

45°

Fig. 14 ATR_2_12_0168_0

For installations on which Ftstat-max is > Ftzul-stat, the permitted load and possible
constructive measures must be clarified with TK Aufzugswerke GmbH on re-
quest.

4.1.9 Gear efficiency

The specified gear efficiencies ηG and ηG´ are extreme values which are to be
applied for dimensioning the motor, frequency inverter and braking resistor,
etc. The rated efficiency ηn provides information on the value ηG that can be
achieved under optimum operating conditions.
The efficiencies ηan and ηan' describe the state of gear starting (overcoming
static friction or build-up of lubricating film in the gear teeth; with ηan values <
0.5 - the gear, when stopped, must be viewed as self-inhibiting).
▪ ηg: minimum design efficiency, driving
▪ ηg´: maximum design efficiency, driven (braking)
▪ ηn: rated efficiency - driving
▪ ηan: starting efficiency – driving
▪ ηan': starting efficiency – driven

Ratio / ηg ηg' ηn ηan ηan'

Speed (rpm) 800 - 1249 1250 -1800 800 - 1249 1250 -1800 1250 -1800 - -
46:1 0.68 0.70 0.70 0.72 0.73 0.39 -0.08
32:1 0.72 0.74 0.74 0.76 0.77 0.46 0.18
41:2 0.80 0.82 0.82 0.84 0.85 0.56 0.47

TK Elevator
BA, TW45 | 6231003860 | 03/2023
 Technology
36 Mechanical data

Ratio / ηg ηg' ηn ηan ηan'

40:3 0.86 0.88 0.88 0.90 0.91 0.66 0.66
32:3 0.87 0.89 0.89 0.91 0.92 0.67 0.67
Tab. 11 ATR_1_21_0051_0

4.1.10 Mass moment of inertia

Machine
Jrot Machine room
location
ASY TW45C winch 1) (kgm2) 0.0045 x
Motor 5.2 kW (kgm2) 0.018 x
2
Motor 7.0 kW (kgm ) 0.024
2
Handwinding wheel D270 (kgm ) 0.01 x
2
ASY complete machine (kgm ) - 0.0325
Tab. 12 ATR_1_21_0049_0

The following values for the machine apply to the ISIS1 versions depending on
the motor construction size:
▪ E 5.5 Jrot = 0.028 kgm²
▪ E 7.5 Jrot = 0.036 kgm²
▪ E 11.0 Jrot = 0.040 kgm²
The mass moment of inertia for versions of the machine not listed in the table
is to be determined according to the details of the individual components.

4.1.11 Weight
Machine location Weight [kg] Machine room
1)
ASY TW45C winch 120 x
2)
ASY TW45C winch 160 x x
Motor 5.2 kW 50 x x x
Motor 7.0 kW 60
Traction sheave D590 60
Traction sheave D520 55 x x
Traction sheave D440 45 x
ASY complete machine [kg] - 225 275 285
Tab. 13 ATR_1_21_0007_0

1)
Version without emergency brake.
2)
Version with emergency brake, NBS

The following values for the machine apply to the ISIS1 versions depending on
the motor construction size:
▪ E 5.5 m = 227 kg
▪ E 7.5 m = 240 kg
▪ E 11.0 m = 245 kg
The overall mass for versions of the machine not listed in the table is to be de-
termined according to the weight data of the individual components.

TK Elevator
BA, TW45 | 6231003860 | 03/2023
Technology
Mechanical data 37

4.1.12 Noise levels

The airborne noise levels in the machine room at a distance of 1 m for the
standard version of the machine TW45C with operation at normal rating are:

Version [dB(A)] Motor speed n1

approx. 63 ≤ 1250 rpm
TW45C approx. 65 ≤ 1500 rpm
approx. 67 ≤ 1800 rpm
Tab. 14 ATR_1_21_0015_0

ATR_1_22_032_0

TK Elevator
BA, TW45 | 6231003860 | 03/2023
 Technology
38 Dimensions

4.2 Dimensions

4.2.1 Machine
Machine room version / vertical motor position

Fig. 15 ATR_2_21_0034_0

Item Designation Item Designation

Screwed connections - machine base frame
2 3 with DT = 440 / 520 / 590
M16 -8.8
Manual brake release for Mayr brake
5
RSZ125-2x50 Nm

TK Elevator
BA, TW45 | 6231003860 | 03/2023
Technology
Dimensions 39

Machine room version / horizontal motor position

Fig. 16 ATR_2_21_0035_0

Item Designation Item Designation

Traction sheave position on right, mirror-in- Screwed connections - machine base frame
1 2
verted to A-A M16 -8.8
3 with DT = 440 / 520 / 590
Manual brake release for Mayr brake Clearance for manual release of the emer-
5 6
RSZ125-2x50 Nm gency brake, NBS

TK Elevator
BA, TW45 | 6231003860 | 03/2023
 Technology
40 Dimensions

ISIS1 version (MRL – machine in the shaft pit)

Fig. 17 ATR_2_12_0152_0

TK Elevator
BA, TW45 | 6231003860 | 03/2023
Technology
Dimensions 41

Machine room version with horizontal rope departure direction

Fig. 18 ATR_2_12_0153_0

(Adjustable range of the upper rope guard +/- 15° to the horizontal)

TK Elevator
BA, TW45 | 6231003860 | 03/2023
 Technology
42 Dimensions

4.2.2 Machine base frame

Machine base frame without rope pulley

Fig. 19 ATR_2_21_0041_0

Project planning dimensions:

Project planning dimen-
Traction sheave version Unit Machine arrangement
sion
DT left right
(mm) z1 z2 x1min x1max x2min x2max
440 52 332 52 332
520 (mm) 200 225 52 252 52 252
590 57 177 57 177
Tab. 15 ATR_1_21_0019_0

Intermediate values for x1 and x2 in the modular dimension of 40 mm possible

TK Elevator
BA, TW45 | 6231003860 | 03/2023
Technology
Dimensions 43

Machine base frame with rope pulley - right-hand version of the

rope pulley position

Fig. 20 ATR_2_21_0042_0

TK Elevator
BA, TW45 | 6231003860 | 03/2023
 Technology
44 Dimensions

Project planning dimensions:

Traction sheave ver-
Unit Rope pulley version (mm)
sion
Diameter of traction
D360 D450
sheave Dt [mm]
ASL α ASL α ASL α ASL α
min max max min min max max min
(mm) /
440 592 149 576 168 150
(°)
167 832 776
(mm) /
520 672 154 616 170 157
(°)
Tab. 16 ATR_1_21_0020_0

Intermediate values for ASL in the modular dimension of 40 mm possible.

Distances:

Rope pulley version Unit Project planning dimension

(mm) x1 x2 y1 y2 z1
D360 (mm) 130 61 645 190 245
D450 (mm) 231 116 600 235 255
Tab. 17 ATR_1_21_0021_0

TK Elevator
BA, TW45 | 6231003860 | 03/2023
Technology
Dimensions 45

Machine base frame with rope pulley - left-hand version of the

rope pulley position

Fig. 21 ATR_2_21_0043_0

Project planning dimensions:

Traction sheave ver-
Unit Rope pulley version (mm)
sion
Diameter of traction
D360 D450
sheave Dt [mm]
ASL α ASL α ASL α ASL α
min max max min min max max min
(mm) /
440 592 149 576 168 150
(°)
167 832 776
(mm) /
520 672 154 616 170 157
(°)
Tab. 18 ATR_1_21_0020_0

TK Elevator
BA, TW45 | 6231003860 | 03/2023
 Technology
46 Dimensions

Intermediate values for ASL in the modular dimension of 40 mm possible.

Distances:

Rope pulley version Unit Project planning dimension

(mm) x1 x2 y1 y2 z1
D360 (mm) 130 61 645 190 245
D450 (mm) 231 116 600 235 255
Tab. 19 ATR_1_21_0021_0

TK Elevator
BA, TW45 | 6231003860 | 03/2023
Transportation and storage
Packaging 47

5 Transportation and storage

5.1 Packaging
NOTICE
Rust on components of the drive!
Damage and possibly loss of function of the product.
Check the "anti-corrosion foil" for damage.

In the case of larger traction sheaves, the gear housing is bolted onto wooden
blocks.

Fig. 22 ATR_2_21_0044_0

The gear housing is bolted directly onto the pallet (special pallet 1200x800)

Fig. 23 ATR_2_21_0045_0

Further packaging depends on the order and is country-specific (air/sea/land

freight).
Refer to the delivery note for the dimensions and weight.
Observe the symbols attached to the packaging or in visible locations.
Dispose of used packing material in an environmentally responsible man-
ner.

i Specific transport equipment and shipping braces remain with the customer.

TK Elevator
BA, TW45 | 6231003860 | 03/2023
 Transportation and storage
48 Transport

5.2 Transport
NOTICE
Improper transport!
Damage and possibly loss of function of the product.
Do not place heavy objects on the assembly when packaged.
Protect it against impacts and falling.
Protect it against water and extreme temperatures  .
Comply with safety regulations.
Pay attention to the centre of gravity of the product.

5.3 Fork-lift truck transport

WARNING
Protruding or tilting parts.
In the event of impact, transported goods can lead to severe crushing injuries
or cuts and possibly fatal injuries.
When effecting transport with a fork lift, use adequately long forks to
prevent tipping over.
During transport, keep a safe distance to persons.
Always pick up at the frame or transport pallet with the forks, not the
machine itself.

5.4 Crane transport

WARNING
Suspended load!
Falling transported goods can lead to severe crushing injuries or cuts and
possibly fatal injuries.
Do not walk underneath suspended loads.
Only use tested and adequately dimensioned lifting gear.
The specified means of transport are only configured for transportation
of the machine, the installed brake and traction sheave. Do not use them
to transport any other loads.

Dimensions and weight

1. Specified weights, see packaging with label.
2. Dimensions, see delivery note.
3. Approximate specifications, see Chap. 4.1.11 P. 36.
4. Machine without frame on rope with transport eyelets (eyebolts). Do not
secure the machine at the facing threads of the shafts.
5. In the case of a machine that is mounted on the machine base frame, at-
tach a transport rope to the base frame.

TK Elevator
BA, TW45 | 6231003860 | 03/2023
Transportation and storage
Checking the delivery 49

6. Secure the machine against slipping and falling over.

7. In the case of machines without a machine base frame, attach a transport
rope to the transport eyebolts.

Fig. 24 ATR_2_21_0046_0

8. Use the thread fitted below the vertical version of the motor for transport
hooks.
NOTICE!
Do not damage the handwinding wheel. Ropes or chains must not
make contact with the handwinding wheel during transport.
9. Use the transport hanger with the horizontal version.

5.5 Checking the delivery

WARNING
Severe transport damage to the product.
Can lead to a malfunction of the product and thus to death or serious injury.
Before commissioning, ensure that there is no severe damage to the
product.

TK Elevator
BA, TW45 | 6231003860 | 03/2023
 Transportation and storage
50 Intermediate storage

1. Check delivery for completeness.

2. Compare with the ordering and delivery documents.
3. Check the packaging for damage and any other conspicuous anomalies.

In the case of damage

1. Do not commission a damaged product.
2. Any damage that is determined is to be documented immediately by
means of a sketch, photo or description of the damage.
3. Report damage to the manufacturer.

5.6 Intermediate storage

▪ The product may be exposed to a maximum relative air humidity of 60%
(at 20 °C).
▪ Store the product carefully in a protected location:
– Protect it against the formation of condensation and moisture.
– Protect against dirt in the machine.
In the case of downtimes of longer than 1 year, carry out standstill main-
tenance Chap. 9.1 P. 74.

TK Elevator
BA, TW45 | 6231003860 | 03/2023
Installation
Setting up the machine base frame 51

6 Installation
6.1 Setting up the machine base frame
To reduce noise and sound transmission, we offer insulation elements that
can be inserted between the frame supports and floor. These differ according
to the type of mounting:
▪ A rubber block 100 x 100 x 50 high without base is used to mount the
drive on the machine room floor without a cement floor or directly sur-
face-mounted on the cement floor.
▪ For installation on cement floor, packing cast into cement floor (thickness
≤ 60 mm). The packing component must be cast in when installing the ce-
ment floor. A rubber block 100 x 100 x 50 with additional packing 140 x
140 x 80 mm is used here.
The number and arrangement of rubber elements is based on the total load
and the distance between the rope lengths (ASL dimension = distance
between rope departures).
When arranging the supports, the overall centre of gravity must lie within the
rubber elements.
The arrangement under the machine base frame should be such that the
stress and/or buffering of the insulation elements (maximum difference 3 - 5
mm) is as even as possible.

6.2 Aligning the machine

The machine is to be set up according to the general arrangement drawing.
The rope departure from the traction sheave is to be aligned plumb to the el-
evator car mounting or the elevator car rope pulley and the counterweight ac-
cording to the drawing. With load applied to the ropes, the machine should be
aligned vertically on its installation surface. Irregularities are to be balanced
out by inserting shims under the floor support.
SA9 traction sheave in the shaft, machine with extended traction sheave shaft
and pedestal bearing.
1. Fitting and mounting of the compensation supports.
2. Horizontal alignment of the traction sheave shaft.
3. Align the bearings of the machine and the outside bearing exactly.

TK Elevator
BA, TW45 | 6231003860 | 03/2023
 Installation
52 Mounting the frame with rope pulley

6.3 Mounting the frame with rope pulley

NOTICE
One-sided load on component and or drive set up on a slant!
Failure of the drive involving damage.
The drive must be horizontal.
Use a spirit level to check; add support if necessary.
Secure the drive on the machine base frame against shifting with ad-
justing screws or stops.
Arrange the suspension ropes symmetrically on the suspension plate,
traction sheave and rope pulleys.

TK Elevator
BA, TW45 | 6231003860 | 03/2023
Installation
Mounting the frame with rope pulley 53

1 2

Fig. 25 ATR_2_21_0215_0

Item Designation Item Designation

1 Left-hand version 2 Right-hand version
1. The version can be found in the general arrangement drawing.
2. Loosely assemble the supplied frame in the machine room.
3. Mount the supports with additional drilled holes and pulley support on the
side of the diverter pulley.
4. Mount and secure the diverter pulley with axle on the pulley supports.

TK Elevator
BA, TW45 | 6231003860 | 03/2023
 Installation
54 Mounting the rope guard

5. Position the frame in accordance with general arrangement drawing on

the insulation elements.
6. Lift the machine onto the frame with lifting gear.
The traction sheave must rest on the diverter pulley side.
7. Move the machine sideways on the base frame until the required ASL di-
mension (parallel gap between the ropes at the rope departure) is
reached.
8. Bolt the machine onto the frame, whereby the machine housing must not
be tensioned.
Use the supplied shims for compensation.
9. Align the rope grooves of the traction sheave and diverter pulley in paral-
lel.
10. Tighten the bolts with the required torque.
11. Plumb the rope departure on the rope pulley and/or mounting on elevator
car and counterweight.
12. With a horizontal rope departure, the gear housing on the machine base
frame is to be secured against shifting by means of end stops.

6.4 Mounting the rope guard

Fig. 26 ATR_2_21_0051_0

1. Use the enclosed screws to bolt the rope guard onto the rope guard car-
rier.
2. Pivot the rope guard carrier to set the guard in such a way that the gap
between the rope and guard on the rope run-in and run-out side of the
traction sheave is as small as possible (1-2 mm).
3. Adapt the inclined pulling location of the rope guard carrier by remounting
the changed rope pull direction.
4. Align the winch and tighten the securing bolts of the rope guard carrier
with the prescribed torque Chap. 10.1 P. 75.

For machines with rope run-in direction of 0 - 90° above the horizontal (e.g.:
(machine arrangement up/down beside), an additional rope guard is required to
i prevent foreign bodies entering between the rope and groove. If the rope run-in
zone is protected within the machine base frame, the function "protection
against injury" is not required.

TK Elevator
BA, TW45 | 6231003860 | 03/2023
Installation
Rope pulley on the machine base frame 55

The rope guards on the rope pulley are to be mounted according to the same
specifications.

6.5 Rope pulley on the machine base frame

All rope guards can be used for the ASL range of .
1. Mount the rope guards on the machine base frame.
2. Set the rope guard by pivoting or remounting in such a way that the clear-
ance between the rope and hoop guard does not exceed a maximum of 2
mm over the entire width of the traction sheave.
3. Set the rope guard with a maximum angle of 15° at the rope entry point
and rope departure point.
If the angle between the rope entry point and rope departure point is
greater than 90°,
fit a third rope guard if the angle between the rope entry point and
rope departure point is greater than 90°.
The angle between all rope guards must be less than 90°.
4. After alignment, tighten the securing bolts of the rope guards with the
prescribed tightening torque.
5. With inclined pulling, adapt the location of the rope guard carrier by re-
mounting the changed rope pull direction.

6.6 Shift protection on the machine base frame

The fastening materials (Hilti HST M16/25 or Fischer M16/25 FAZ II) are in-
cluded in the scope of supply and must be attached to the unfinished floor.
Comply with the installation instructions of the manufacturer.

i In locations where the distance to the wall is < 250 mm, the standard shift pro-
tection devices must be replaced by devices for low wall clearances.

The shift protection is configured for the following machine insulations:

▪ Insulation elements without underlay for machine room without floor
pavement
▪ Insulation elements with underlay for machine room with floor pavement
(≤ 60 mm height); support made from Multiplex laminated wood
140x140x80 mm.

TK Elevator
BA, TW45 | 6231003860 | 03/2023
 Installation
56 Electrical connection

max. 5 mm
4

3
2
4

Fig. 27 ATR_2_00_0002_0

Item Designation Item Designation

1 Shift protection 2 Machine base frame
3 Anchoring device 4 Alternative holes
1. Position the shift protection elements contact-free with a slight clearance
(maximum 5 mm) to the machine base frame and make marks.
2. Drill holes for the anchoring devices at the marked positions.
If there is steel reinforcement in the concrete, use alternative holes.
3. Secure the shift protection elements with 2 anchoring devices.
Use 1 anchoring device per tab.

6.7 Electrical connection

WARNING
Inadequate connection
Electric shock. Damage to drive.
Earth the motor and brake magnet in accordance with country-specific
regulations.
Electrical connections must correspond to at least the protection class in
accordance with the name plate and/or required country-specific protec-
tion class.

TK Elevator
BA, TW45 | 6231003860 | 03/2023
Installation
Electrical connection 57

WARNING
Live parts!
Electric shock.
When connecting the machine, comply with the relevant regulations.
Never work when the voltage is switched on!
Ensure reliable earthing (loop resistance).
Here, configure connections in both terminal boxes.

6.7.1 Connecting the machine

NOTICE
Incorrectly connected cables!
Can lead to impairment or loss of function of the product.
On connecting the motor, comply with the terminal connecting plan on
the back of the cover on the motor terminal box and/or the motor con-
nection terminal diagram.
In the case of frequency-controlled machines, ensure EMC-compliant in-
stallation of the motor and posistor (use suitable shielding).

Motor connection box - Make: CEG

Representation in star circuit Υ and various versions. If necessary, reconnect
in delta section Δ according to wiring diagram

4 3 2 1

10

5+6
11

4 9 8 7
Fig. 28 ATR_2_21_0052_0

Item Designation Item Designation

1 U1 2 V1
3 W1 4 Connection for PE conductor
5 Posistor temperature sensor 6 Posistor temperature sensor
7 W2 8 U2

TK Elevator
BA, TW45 | 6231003860 | 03/2023
 Installation
58 Electrical connection

Item Designation Item Designation

Connection for brake mi-
9 V2 10
croswitch
Connection for brake magnet
11
coil

230 / 460 V motors made by EMOD

Drehstrommotor
Three phase motor Art.: 218860
2U 2V 2W

Schaltung
connection U5 V5 W5
Parallel /
parallel
niedrige Spannung /
low voltage 1U 1V 1W
L1 L2 L3
L1; L2; L3 = Motoranschluss / connection of motor
2U 2V 2W

Schaltung
connection

Reihe / U5 V5 W5
series
hohe Spannung /
1U 1V 1W
high voltage
L1 L2 L3
L1; L2; L3 = Motoranschluss / connection of motor

Anschluss der Kaltleiterfühler /

connection of thermistor protection
1 2
1+2 Kaltleiteranschluss / connection of thermistors
Keine Spannung über 2,5V anlegen /
Only apply voltages ≤2.5V

Fig. 29 ATR_2_12_0160_0

6.7.2 Connecting the motor line

1. Strip the insulation from the connection line.
2. Route cable through the cable gland.
3. Connect the PE conductor to the screwed connection specifically de-
signed for the purpose.
4. Connect the three motor wires to the terminals U, V and W as specified in
the terminal connecting plan.
5. Pull the shielding braid evenly over the lamellar insert.
6. The braid must not protrude beyond the lamellar insert into the thread.
7. Pull the cable through the cap nut.
8. Push the cap nut over the shielding.

TK Elevator
BA, TW45 | 6231003860 | 03/2023
Installation
Electrical connection 59

9. Tighten the cap nut with the recommended torque in accordance with
manufacturer documentation Chap. 10.2 P. 75.

2 3

1 4

Fig. 30 ATR_2_21_0055_0

Item Designation Item Designation

1 Cable with shielding braid 2 Lock nut
3 Lamellar insert 4 Cap nut

6.7.3 Connecting the posistor

NOTICE
Overvoltage at the measuring device!
Defective measuring device.
Do not apply a voltage greater than 2.5 V.

A triggering device (motor protection device) is required for evaluation of the

posistor temperature sensor installed in the motor.
1. Strip the insulation from the connection line.
2. Connect both wires in accordance with the terminal connecting plan.
3. Tighten the cap nut with the recommended torque in accordance with
manufacturer documentation Chap. 10 P. 75.

6.7.4 Connecting the brake

Connect the brake (coil and microswitch) via the motor terminal box
Chap. 6.7.1 P. 57.

Emergency brake NBS (optional)

If the emergency brake system is fitted, a description with all the details regard-
i ing connection and operation of the emergency brake can be found in the sep-
arately enclosed operating manual for the emergency brake system, NBS.

TK Elevator
BA, TW45 | 6231003860 | 03/2023
 Work on the product
60 Testing the brake

7 Work on the product

7.1 Testing the brake
(At least once a year within the framework of central maintenance)

Test the braking deceleration at each brake circuit

WARNING
Elevator car movement by means of specific brake release.
The elevator car can move in an uncontrolled manner through the shaft.
Be prepared to brake at all times.
Regulate the travel speed of the elevator car by opening/closing the
brake manually if manual brake release is present.
The movement of the elevator car must be slow (0.3 m/s).
Immediately deactivate the live coils and check the brake.

1. Signs indicating that maintenance work is under way must be attached to

the elevator at all landing doors.
2. All doors must be properly and adequately locked.
3. Check that no persons are in the elevator car.
4. Position the elevator car at least two floors below the top landing.
5. For the single-circuit test with lever for the Mayr brake, ensure that the
brake magnet coil is connected with inrush/holding voltage (180 V / 90 V).
6. Test the brake circuit separately.
The brake of the brake circuit not being tested must remain open dur-
ing the entire test operation.
This is done by applying holding voltage to the magnet coil of the brake
circuit that is not involved.

Test the braking deceleration on one brake circuit in each case

1. Initiate normal travel (brake to be tested is opened).
2. After the rated speed has been reached, trigger an emergency stop (brake
to be tested closes).
3. Determine the deceleration value for the 1st brake circuit with the measur-
ing device.
4. Compare the measurement result with the default value.
5. Compare the measurement results with the default values.
6. Disconnect the permanent voltage supply of the continuously opened 2nd
brake circuit.
7. Connect the permanent voltage supply on the 1st brake circuit.
8. Connect the measuring device to the 2nd brake circuit.
9. Repeat the test operation on the 2nd brake circuit.
10. Re-establish the original state of the circuit (operation of both brakes sim-
ultaneously).

TK Elevator
BA, TW45 | 6231003860 | 03/2023
Work on the product
Replacing the brake 61

Testing of both brake circuits

Deceleration values for brake circuits
▪ The minimum deceleration value for one brake circuit is approx. 0.4 m/s²
▪ The minimum deceleration value for both brake circuits is approx. 1.0 m/s²
1. Run a brake test with both brake circuits by triggering emergency braking.
The deceleration values must be significantly higher than values de-
termined in the individual test.

Check for wear

1. Use a feeler gauge to check the air gap between the coil body and arma-
ture base plate with the brake closed (coils without current).
2. Repeat the operation at different positions.
Nominal air gap: Brake closed (without current), new lining.
Limit air gap: Brake closed (without current), lining worn.
Test air gap: Brake opened (under voltage), minimum distance
between friction lining and contact surface.
3. Replace the complete brake if the limit air gap has been reached.
Repairs can only take place at TK Aufzugswerke GmbH.

7.2 Replacing the brake

7.2.1 Mayr brake

When the wear limit (1.0 mm / gap) is reached or there is a defect in the brake,
the complete brake is to be replaced in all cases.
1. Installation and removal, see Chap. 10 P. 75.

TK Elevator
BA, TW45 | 6231003860 | 03/2023
 Work on the product
62 Replacing the brake

2. Check the brake before commissioning the installation.

Fig. 31 ATR_2_12_0062_0

Item Designation Item Designation

1 Motor shaft 2 Coupling hub (motor side)
3 Elastic gear ring 4 O-rings for brake rotors
5 Brake rotor brake circuit 2 6 Brake cover plate
7 Brake rotor brake circuit 1 8 Worm shaft
Screwed connection bearing
9 Bearing cover 10
cover
Return spring for manual release Switch bracket for manual re-
11 12
with mounting parts lease with mounting parts
Switch bracket for manual re- Manual release lever with
13 14
lease with mounting parts mounting parts

TK Elevator
BA, TW45 | 6231003860 | 03/2023
Work on the product
Checking the oil level 63

Item Designation Item Designation

Fastening screws
15 Anchor disc 16
Brake 3x M8 -8.8
Earth braid with screwed con-
17 Magnetic coil 18
nections
19 Setting screw for microswitch 20 Microswitch
During work on the brake, comply with information and details of the brake
manufacturer Chap. 10 P. 75.

7.3 Checking the oil level

Check the oil level.
The oil level should be ± 5 mm outside of the centre.
To top up, the machine should be out of service for 5 minutes.

Fig. 32 ATR_2_12_0319_0

7.4 Lubrication
NOTICE
Bearing damage!
Damage to the gear due to unsuitable lubricant.
Only use the specified gear oil.

i Initial lubrication took place on delivery.

Motor position/filling
Lubricant Replacement interval
quantity
For the first time after 4 vertical approx. 5.0 litres
Synthetic gear oil years
SM1 horizontal approx. 4.0
then every 8 years litres
Tab. 20 ATR_1_21_0024_0

WARNING
Danger of scalding
Long-term car operation heats up the oil!
During work on the drive, wait until the housing has cooled down, if ne-
cessary.

1. Heat the gear to operating temperature (approx. 35°C) before replacing.

TK Elevator
BA, TW45 | 6231003860 | 03/2023
 Work on the product
64 Lubrication

2. Drain off the gear oil by removing the cap on the oil drain pipe.
3. Collect the old oil in a container specifically designed for the purpose.
4. Empty the gear and close off the oil drain pipe with PTFE sealing tape.
Check for leakage.
5. Remove the red locking screw "OIL" and fill the gear housing until the pre-
scribed oil quantity is reached.
6. Remove upper handhole cover and fill the gear housing until the pre-
scribed oil quantity is reached.
7. Check the level at the oil gauge glass.
8. Use the dipstick to check the level.
9. Never mix different types of oil
10. Do not dispose of oil where it can enter the groundwater.
11. Dispose of old oil as well as cloths contaminated with oil and grease ac-
cording to prevailing regional regulations.
12. Use the gear oil SM1/220 approved by TK Aufzugswerk GmbH.
13. TK Aufzugswerke GmbH will not be held liable for damage resulting from
the use of non-approved lubricants.

Vertical motor position

3 2
Fig. 33 ATR_2_12_0059_0

Item Designation Item Designation

6 1 Ventilation, filling opening 2 Oil gauge glass
3 Oil drain 4

TK Elevator
BA, TW45 | 6231003860 | 03/2023
Work on the product
Checking the backlash 65

1 1

2 3
Fig. 34 ATR_2_12_0060_0

4 5 Item6 Designation Item Designation

1 Ventilation, filling opening 2 Oil gauge glass
3 Oil drain 4

7.5 Checking the backlash

7 8 If the running performance deteriorates, this might have been caused by ex-
cessive backlash in the worm gear toothing.
Wear on the worm wheel gear toothing changes the existing tooth thickness
and this can be determined using the following measurement of the backlash.

NOTICE
Backlash too great!
Teeth on worm wheel worn; deterioration in running performance.
If the running performance deteriorates (noises, jerking, etc.), measure
the backlash.
If a wear limit value (backlash) of 1.5 mm is reached, replace the toothing.

1. Disconnect the power from the installation and secure it against reactiva-
tion.
2. Secure the car and counterweight against movement.
3. Take the load off the traction sheave.
The traction sheave must be free to move.
4. Perform the measurement with the service brake closed.
5. Release the emergency brake, if present.
6. Fit a measuring attachment to the traction sheave, e.g. screw clamp.
7. Specify the measuring radius (M) and mark the measuring point.
The radius (r) for the TW45C = 95 mm.
8. Attach a dial gauge with magnet stator at the gear drive housing and align
to the measuring point (M).
9. Turn the traction sheave by hand until the dial gauge pointer moves.
10. Move the traction sheave back and forth until resistance is felt.
11. Read off the dial gauge (ME).

TK Elevator
BA, TW45 | 6231003860 | 03/2023
 Work on the product
66 Replacing the traction sheave

12. Use the formula below to calculate the backlash.

Backlash = (ME*r)/M

Fig. 35 ATR_2_22_0027_0

Item Designation Item Designation

M Radius ME Measurement result
Radius – worm wheel, all dimen-
r
sions in mm

7.6 Replacing the traction sheave

WARNING
Traction sheave not resting properly on cone (is loose)!
Traction sheave tumbles and can come loose. The elevator car can move in
an uncontrolled manner through the shaft.
Do not change the dimension of the feather key, groove, cone shaft or
traction sheave bore hole under any circumstances.
Avoid damage to and contamination of the cone shaft and traction
sheave.
Secure the traction sheave with a chain or ropes.
Ensure correct installation.

1. Disconnect the power from the installation and secure it against reactiva-
tion.
2. Secure the car and counterweight against movement.
1. Remove cover plate on the traction sheave.
2. Take the load off the traction sheave.
3. Take off the ropes.
4. Remove the fastening screws with tension disc.
5. Insert the fastening screw in the tension disc the other way around.
6. Screw the threaded rod into holes for forcing.
7. Tighten threaded rods alternately.

TK Elevator
BA, TW45 | 6231003860 | 03/2023
Work on the product
Replacing the traction sheave 67

Installation of the traction sheave

1. Clean the shaft end and traction sheave bore hole (free of oil, grease,
paint)
Do not apply grease or oil to the shaft and hub.
2. Place the new traction sheave on the conical shaft end of the motor shaft.
3. Align the locations of the feather key and groove in relation to one an-
other.
4. Push the traction sheave onto the motor shaft.
1. Use the supplied new microencapsulated screw and detent edged wash-
ers to attach the tension disc to the motor shaft at the inner circle of
holes.
2. Comply with the prescribed tightening torque of 90 Nm.
3. Comply with the prescribed tightening torque of 160 Nm (with NBS emer-
gency brake system 190 Nm).
4. Comply with the prescribed tightening torque of 250 Nm.
Compare torque with drawing.

Fig. 36 ATR_2_12_0063_0

Item Designation Item Designation

1 Fastening screw 2 Hole for forcing screw
3 Traction sheave 4 Tension disc
5 Rope guard plate 6
1. Release the mounting of the traction sheave from the lifting gear.
2. Hang up the ropes on the traction sheave.
3. Fit the rope guard plates.
4. Align the rope guard plates.
5. Remove the securing devices from the car and counterweight.

TK Elevator
BA, TW45 | 6231003860 | 03/2023
 Work on the product
68 Replacing the motor

7.7 Replacing the motor

i Order a motor with coupling hub on the motor side. Motors of the make CEG
general include a clutch hub.

Disassembly
1. Disconnect the power from the installation and secure it against reactiva-
tion.
2. Secure the car and counterweight against movement.
3. Attach and secure the motor to the lifting gear.
4. Unplug the electrical connections and lines from the motor.
5. Undo the nuts of the motor mounting on the housing flange.
6. Undo the bolts of the flexible coupling.
In the case of the flexible coupling, the elastomer part of the coupling
remains screw-connected to the brake disc.
7. Carefully pull the motor off the coupling connection.
8. If the replacement motor was delivered without a handwinding wheel and
encoder, remove these from the old motor and, including the encoder
mount (clip nut), use them for the new motor.

Installation
1. Place the replacement motor ready for use.
2. Compare the motor data.
3. Attach and secure the motor to the lifting gear.
4. Align the motor to the coupling and housing flange of the gear.
5. By turning the motor shaft, align the lightly greased coupling halves to one
another (tooth to gap; the elastic gear ring must be located between the
clamps of the two coupling halves.)
6. Push the motor and gear coupling together.
7. The locations of the mounting holes must match those of the screws.
8. Push on the motor until the face of the motor contacts the gear flange or
flange ring.
9. Mount the motor on the gear flange.
10. Tighten the nuts evenly alternately and cross-wise up to the prescribed
tightening torque Chap. 10.1 P. 75.
11. Connect the connection line in the terminal box.
12. Make the electrical connections as per terminal connecting plan Installa-
tion.
13. Establish the connections of the brake and encoder to the control system.
14. Check the function of the brake before commissioning.

TK Elevator
BA, TW45 | 6231003860 | 03/2023
Work on the product
Replacing the encoder 69

7.8 Replacing the encoder

4

5 8
2
6 1
7
Fig. 37 ATR_2_12_0064_0

Item Designation Item Designation

1 Fan hood of motor 2 Encoder
Central screw for handwinding
3 Handwinding wheel with hub 4
wheel mount
5 Encoder mount (spring plate) 6 Screw for encoder mount
Studs for mounting encoder on
7 Clip nut 8
shaft

Disassembly
Preparatory measures
1. Disconnect the power from the installation and secure it against reactiva-
tion.
2. Unplug the encoder connection cable at the frequency inverter.
3. Remove the central screw in the middle of the handwinding wheel hub.
4. Pull the handwinding wheel with hub off the motor shaft.
5. Release the two studs at the collar of the encoder inner ring (do not re-
move completely).
6. Unscrew the cylinder head screw at the bracket of the encoder mount.
7. Remove the cable ties holding back the cables.
8. Pull the encoder off the end of the motor shaft.
9. Check that the technical data of the new encoder match

Installation
1. Fit the encoder mount (spring plate) of the removed encoder onto the new
encoder.
2. Push the new encoder onto the cleaned shaft end of the motor until it
makes contact with the shaft collar.
3. The mounting collar must point towards the shaft end.
4. Screw on the encoder mount at the motor.
5. Secure the encoder inner ring by tightening the stud on the motor shaft.
6. Push the handwinding wheel with hub onto the shaft end.

TK Elevator
BA, TW45 | 6231003860 | 03/2023
 Work on the product
70 Checking for grease/oil leakage

7. Align the hub to the axial pin in the shaft and mount the hub with hand-
winding wheel by means of the central screw and disc; tighten with 75
Nm.
8. Secure the connection line to the motor with cable ties.
9. Connect the encoder connection cable to the frequency inverter.

7.9 Checking for grease/oil leakage

WARNING
Loss of the brake function!
The elevator car can move in an uncontrolled manner through the shaft.
Make sure the brake drum and other components of the brake are free of
grease and oil.
Rectify the cause of grease/oil leakage.
Run the brake test.
Replace the contaminated brake.

NOTICE
Danger when using commercially available brake cleaning agents!
Damage to the brake
For cleaning work on the brake, only use the cleaning agent isopropanol
(isopropyl alcohol). Observe the information provided by the brake man-
ufacturer Appendix.

Degree of contamination Procedure

Every 3 months
If a small amount of oil/grease Clean and check regularly within the (and/or every 6 months in the case
leakage is determined framework of maintenance of low frequency of use: fewer than
50,000 runs per year)
Clean the machine and, if necessary,
the brake, and repair as quickly as
possible.
Before continuing operation until
If a large amount of oil/grease
modification, run a brake test. If the
leakage is determined or brake
braking effect is inadequate: Shut Repair after 4 weeks at the latest
disc/brake linings are already
down installation.
fouled with oil/grease
If necessary, check on a daily basis
whether oil/grease is still leaking. If
this is the case: Shut down installa-
tion.
Tab. 21 ATR_00_0004_0

See manufacturer's instructions Chap. 10 P. 75

TK Elevator
BA, TW45 | 6231003860 | 03/2023
Work on the product
Blocking clamp 71

7.10 Blocking clamp

NOTICE
Blocking clamp not removed.
Can lead to impairment or loss of function of the product.
Remove the blocking clamp after completion of the installation work.

A blocking clamp that matches the traction sheave (rim width and design) is
part of each machine

Deployment of the blocking clamp

Use the blocking clamp to prevent movements due to slipping ropes during
installation work on the elevator car or counterweight or during work where
the rope traction of the installation is insufficient (e.g. pulling out of the safety
gear).
The blocking clamp is to be pre-tensioned by evenly tightening the two
hexagon nuts until it is excluded that ropes will slip.

Fig. 38 ATR_2_12_0066_0

Item Designation Item Designation

1 Traction sheave 2 Ropes
3 Pressure piece 4 Washer
5 Hexagon nut 6 Spacer sleeve
7 Clamp clip

TK Elevator
BA, TW45 | 6231003860 | 03/2023
 Commissioning
72 Work steps

8 Commissioning
8.1 Work steps
Check the following points:
1. Check the machine, traction sheave and base frame.
2. Check the rope guard.
3. Check the distance to the traction sheave.
4. Check the setup of the machine, base frame, pedestal and rope departure.
5. With a side or oblique rope departure, secure the gear housing against
moving with steady plates and set screws.
6. Tighten the bolts with the required torque Chap. 10.1 P. 75.
7. Check the oil level.
8. Check the installation of filling and/or ventilation screw.
9. Check the power connections and grounding at the motor.
10. Check the connection of the coils and microswitch of the brake.
11. Check the connection values (voltage, frequency) against the manufac-
turer specifications.
12. Check the function of the monitoring devices (encoder, thermal element).
13. Check the parking brake and emergency brake NBS (if present).
14. Check the brake function.
15. Attach the direction arrow (Up/Down) according to the direction of travel
and clearly visible on the motor near the handwinding wheel.
16. Remove safety, auxiliary and installation tools from the danger zone.

i For assembly and repair, use only original parts from TK Aufzugswerke GmbH,
as otherwise no warranty can be provided.

8.2 Emergency operation

Emergency rescue of trapped persons

CAUTION
Rapid movement of the elevator car!
Abrasion injuries.
Only use the handwinding wheel for assembly and maintenance pur-
poses with a safe stance.
In the event of uncontrolled elevator car movement, let go of the hand-
winding wheel immediately.

1. Open the brake; move the brake release lever into its operating position.

TK Elevator
BA, TW45 | 6231003860 | 03/2023
Commissioning
Emergency operation 73

2. The handwinding wheel might also have to be moved to bring the elevator
car into the nearest landing.
3. Depending on the load, the elevator car can begin to move quickly after
opening the brake.
4. Immediately let go of the handwinding wheel and control the speed of the
elevator car by pressing the brake release lever with varying degrees of
force.
5. Following the rescue operation, put the brake release lever back in the rest
position. On the version with perpendicular motor position, additionally se-
cure with the retaining clip.

Drives with brake (make: Mayr) in machine room version (TWR)

without emergency brake, NBS
The TW45C machine room version is equipped for emergency operation with
a handwinding wheel and brake release lever.
Operation of the brake release lever in the direction of the motor releases the
disc brake.

Machine with emergency brake, NBS

Mounting the emergency brake, NBS, fundamentally changes the procedure

i and sequence for emergency operation. Comply with the separate NBS operat-
ing manual. The operating manual for machines with emergency brake system
equipment is delivered separately. Emergency brake system, NBS.

Brake release lever for manual release of machines with Mayr

brake
Chap. 10 P. 75

TK Elevator
BA, TW45 | 6231003860 | 03/2023
 Maintenance
74 Standstill maintenance

9 Maintenance
9.1 Standstill maintenance
If the TW45C is not installed or used for a longer period, the measures de-
scribed below must be carried out every year:
1. Check the oil level; top up if necessary.
2. Change the oil at the prescribed intervals.
3. Clean the ventilation screw on the gear housing; the ventilation opening
must be clear.
4. Check the gear and bearings for leakage
5. Check brake and release gap, maximum 0.6 mm per release gap.
6. Check the brake function
7. Check the braking deceleration
8. Check worm gear toothing for wear
9. Check the backlash between the worm shaft and worm wheel, 0.05 mm
to 0.12 mm at 20°C (max. 1.5 mm)
10. Check the groove profile on the traction sheave for damage and wear
11. Check that the bolts of the traction sheave mount are securely seated
12. With the machine on the machine base frame, check the mount of the ma-
chine, supports and rope pulley carriers.
13. Check the rope pulley grooves for damage and wear.
14. Check that electrical connections are in proper and adequate condition
and check that they are securely attached.
15. Check that protective and safety devices are present and correctly set.
16. Check the seals at the shaft in the area of the brake and at the bearing for
grease and/or oil leakage.

TK Elevator
BA, TW45 | 6231003860 | 03/2023
Appendix
Tightening torques 75

10 Appendix
10.1 Tightening torques
DANGER
Insecure threaded connection.
Death or severe physical injury due to parts coming loose.
When working on the machine or replacing parts, care must be taken to
ensure that the prescribed bolt/screw strength and tightening torques
are complied with.
Only use suitable tools (torque wrench).

The values listed below apply to screwed connections with regular threads
(not fine threads):
▪ Slotted pan head tapping screws DIN 912 ISO 4762
▪ Hexagon head bolts DIN 931/933 ISO 4014/4017
▪ These specifications do not apply to microencapsulated bolts/nuts. The
specifications of the manufacturer apply here.

i If other tightening torques are specified in the drawings or elsewhere in the

document for each screw size, these are to be complied with.

Tightness 8.8 10.9 12.9

Screw/bolt size Tightening torque [Nm]
M4 2.6 - -
M5 5.3 - -
M6 9.0 12 15
M8 20 30 35
M10 40 60 75
M12 75 105 130
M14 120 170 205
M16 190 265 320
M20 370 520 620
M24 640 900 1080
M30 1300 1800 2150
Tab. 22 ASY_1_00_0001_0

10.2 Manufacturer information

Also see about this
Wachendorff encoder WDG100H_38-1024 - Data sheet P. 77

TK Elevator
BA, TW45 | 6231003860 | 03/2023
 Appendix
76 Manufacturer information

Verification of traction sheave calculation P. 78

mayr ROBA-duplostop Size 125 brake - installation and operating manual
P. 79
mayr ROBA-duplostop Size 500 - 1800 brake - installation and operating
manual P. 95
SKINTOP MS-SC Mounting instructions P. 111
Wachendorff encoder WDG100H--xx-yyyy-ABN-I05-K3-D56 - assembly
instructions P. 112
Drehgeber Wachendorf WDG 100H - Datenblatt P. 113
Drehgeber Wachendorf WDG 100H-XX-YYYY - Montageanleitung P. 125
Drehgeber Wachendorf WDG 100H-38-2048.pdf P. 126

TK Elevator
BA, TW45 | 6231003860 | 03/2023
 Wachendorff Automation GmbH & Co. KG
Industriestrasse 7
D-65366 Geisenheim
Tel.: +49 (0) 67 22 / 99 65 - 25
Fax: +49 (0) 67 22 / 99 65 - 70
Hollow shaft Encoder WDG 100H www.wachendorff.de

Specifications
Mechanical Data
Housing
- Servo flange: Aluminium
- Housing: Aluminium,
- Depth: 42 mm
- Attachment: about Hollow-shaft with
2 set screw M4
Hollow shaft
- Material: Stainless steel
- Diameter: : 38 mm
- Loading on shaft- max. 200 N radial
end: max. 100 N axial
- Starting torque: approx.1.5 Ncm at
ambient temperatur
Attachment: 2 x Hub M4, DIN 913
Bearings
- Type: 2 precision ball
Order-No.: WDG 100H-38-1024-AB-R05-K3-J66-100 bearings
10
- Service life: 3 x 10 revs. at 100%
Suggested shaft adjustment: of full rated shaft load
about hollow shaft diameter 38mm: 38m6 (k6, j6) 11
4 x 10 revs. at 40%
Max. concentricity deviation of motor shaft: 0,05 mm 12
3 x 10 revs. at 20%
Speed: max. 3.500 r.p.m.
Thyssen-No.: 9950 001 1304
Weight: ca. 720 g
Connection: radial with 10 m
Electrical data: shielded cable with
5V Power supply: 4,75 ... 5,5 VDC connector
26ET31 (7-pol. Phönix terminal)
1kW 100W 1kW

Current consumption: max. 70 mA

A,B 26LS32 Channels: A, B and
Evaluation

AB inv. Electrical Data

WDG

Output: push-pull General Layout: DIN VDE 0160

Signal Load: max. 40 mA Supply / Output: ® Output circuit
A,B Signal level: bei 20 mA Cable lenght: max. 100 m
H > 2,5 VDC
Ground L < 1,2 VDC Optics
Shield Pulse frequency: max. 200 kHz
Circuit protection: no Light source: IR - LED
Service life: typ. 100.000 hrs.
Scanning: differential
Output circuit: 5 VDC: R05

Accuracy
in % einer Periodendauer des Signals A
Quadratue phasing: 90° + 7,5%
100

Pulse on/off ratio: 50% + 7%

Environmental Data
10000

11 Measured mounted and housing grounded .

ESD (DIN EN 61000-4-2): 8 kV
Burst (DIN EN 61000-4-4): 2 kV
2 x set screw Protection rating (EN 60529): IP54
M 4 x 4 DIN 913 Vibration 50m/s² (10-2000 Hz)
63

(DIN EN 60068-2-6):
3 Shock 1000m/s² (6 ms)
,05
+0 0,03
+
(DIN EN 60068-2-27):
Operating temperature: -20°C to +80°C
Storage temperature: -30°C to +80°C
40
15

Cable connection, 10 m shielded cable

°

37 100
42 Pin arrangemant:
Function Pin Colour
Dimensional drawing WDG 100H, Dimensional specifications in mm.
Negative 6 white
Positiv 7 brown
A 5 green
A
A inv. 4 grey
R05 A B 3 yellow
B B inv. 2 pink
Shield 6 braiding
B

View from shaft end, rotating clockwise.

19.05.14/Specifications without engagement, subject to errors and

Installation and Operational Instructions for
ROBA-stop®-Z Type 892.101.0
Size 125 (E073 01 046 000 4 EN)

Translation of the Original Operational Instructions

Design according to
Drawing number: E073 01 046 000 1 10 Article number: 8227821
Drawing number: E073 01 046 000 1 11 Article number: 8253118 (without hub (12))
Drawing number: E073 01 046 000 1 12 Article number: 8292346 (without hand release (18))

Please read these Operational Instructions carefully and follow them accordingly!
Ignoring these Instructions can lead to lethal accidents, malfunctions, brake failure and damage to other parts.
These Installation and Operational Instructions (I + O) are part of the brake delivery.
Please keep them handy and near to the brake at all times.

Contents: Safety and Guideline Signs

Page 1: - Contents DANGER
- Safety and Guideline Signs
Immediate and impending danger, which can
Page 2: - Guidelines on EU Directives lead to severe physical injuries or to death.

Page 3: - Safety Regulations

Page 4: - Safety Regulations
CAUTION
Page 5: - Safety Regulations
Danger of injury to personnel and
Page 6: - Brake Illustrations damage to machines.
Page 7: - Parts List
Page 8: - Technical Data
- Switching Times
Please Observe!
Page 9: - Application Guidelines on important points.
- Design
- Function
- Scope of Delivery / State of Delivery
- Installation Conditions
Page 10: - Installation
- Adjustment
- Noise Damping
Page 11: - Electrical Connection and Wiring
Page 12: - Permitted Shaft Misalignments
- Shaft Alignment
Page 13: - Braking Torque
- Brake Inspection
- Dual Circuit Brake Functional Inspection
Page 14: - Release Monitoring
Page 15: - Maintenance
- Replacing the Rotors
- Information on the Components
- Cleaning the Brake
Page 16: - Disposal
- Malfunctions / Breakdowns

18/05/2022 TK/HW/SU Chr. Mayr GmbH + Co. KG

Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: +49 8341 804-0, Fax: +49 8341 804-421
Page 1 of 16 www.mayr.com, E-Mail: public.mayr@mayr.de
Installation and Operational Instructions for
ROBA-stop®-Z Type 892.101.0
Size 125 (E073 01 046 000 4 EN)

Guidelines on the Declaration of Conformity

A conformity evaluation has been carried out for the product (electromagnetic safety brake) in terms of the EU Low
Voltage Directive 2014/35/EU and the RoHS 2011/65/EU with 2015/863/EU. The Declaration of Conformity is laid out in
writing in a separate document and can be requested if required.
Guidelines on the EMC Directive 2014/30/EU
The product cannot be operated independently according to the EMC directive.
Due to their passive state, brakes are also non-critical equipment according to the EMC.
Only after integration of the product into an overall system can this be evaluated in terms of the EMC.
For electronic equipment, the evaluation has been verified for the individual product in laboratory conditions, but not in the
overall system.
Guidelines on the Machinery Directive 2006/42/EC
The product is a component for installation into machines according to the Machinery Directive 2006/42/EC.
The brakes can fulfil the specifications for safety-related applications in coordination with other elements.
The type and scope of the required measures result from the machine risk analysis. The brake then becomes a machine
component and the machine manufacturer assesses the conformity of the safety device to the directive.
It is forbidden to start use of the product until you have ensured that the machine accords with the regulations stated in the
directive.
Guidelines on the EU Directive 2011/65/EU (RoHS II) with 2015/863/EU (RoHS III – from 22 July 2019)
These restrict the use of certain hazardous substances in electrical and electronic devices as well as in products /
components (category 11), the proper operation of which is dependent on electric currents and electromagnetic fields.
Our electromagnetic products / components fulfill the requirements laid down in the RoHS Directive(s), taking
into account the valid exceptions (according to Appendix III and IV RoHS (2011/65/EU) with delegated Directives
(EU) 2018/739-741 from 01.03.2018 for Category 11 – until 21 July 2024) and comply with the RoHS.
Guidelines on the ATEX Directive
Without a conformity evaluation, this product is not suitable for use in areas where there is a high danger of explosion.
For application of this product in areas where there is a high danger of explosion, it must be classified and marked
according to Directive 2014/34/EU.
Guidelines on the REACH Regulation (EC) No. 1907/2006
of the European Parliament and of the Council concerning the Registration, Evaluation, Authorization and Restriction of
Chemicals (REACH). This regulation governs the manufacture, placing on the market and use of chemical substances in
preparations and, under certain conditions, also of substances in finished products.
mayr ® power transmission exclusively manufactures products (articles: overload clutches, shaft couplings,
electromagnetic brakes / clutches, permanent magnet motors and the appropriate control modules / rectifiers) in
accordance with the definition in Article 3 of the REACH Regulation.
mayr ® power transmission is aware of its responsibility towards the environment and society. As a matter of precaution,
we pay attention to particularly critical substances in the supply chain and strive to avoid using any such substances
completely or to replace them in the near future.
In compliance with Article 33 of the REACH Regulation, we would like to inform you that in our overload clutches and shaft
couplings, electromagnetic brakes / clutches as well as permanent magnet motors, subcomponents with a lead content of
> 0.1% are or may be used. These are manufactured from raw materials such as machining steel / copper alloys (e.g.
brass, bronze) or aluminum alloys.
Besides high-melting-point (HMP) solders (electronics), this also affects integrated machine elements as well as standard
parts (screws / nuts / set screws / pins / etc.) among others, provided that the relevant standards allow this.
For example, lead can occur as an alloying element with more than 0.1 mass percent, based on the respective total mass,
in screws and set screws of the following property classes: 4.6, 4.8, 5.8, 6.8, 04, 4, 5, 6, 14H, 17H, 22H, 33H, 45H.
Products made from copper and copper alloys do not fall within the area of applicability of Regulation (EC) No. 1272/2008
of the European Parliament and Council on the Classification, Labeling and Packaging of Substances and Mixtures (CLP
Regulation) and are therefore not subject to the classification and labeling obligations.
To our knowledge, when used for their intended purpose and disposed of correctly (recycling), the contained substances
pose no threat to health or environment.
We would like to point out that the proportion of lead used here is not prohibited according to the REACH Regulation. It is
merely necessary to declare the use of this substance.

18/05/2022 TK/HW/SU Chr. Mayr GmbH + Co. KG

Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: +49 8341 804-0, Fax: +49 8341 804-421
Page 2 of 16 www.mayr.com, E-Mail: public.mayr@mayr.de
Installation and Operational Instructions for
ROBA-stop®-Z Type 892.101.0
Size 125 (E073 01 046 000 4 EN)

Safety Regulations
These Safety Regulations are user hints only and may not be complete!

General Guidelines Guidelines for Electromagnetic Compatibility

DANGER (EMC)
Danger of death! In accordance with the EMC directive 2014/30/EU, the individual
Do not touch voltage-carrying lines and components produce no emissions. However, functional
components. components e.g. mains-side energization of the brakes with
rectifiers, phase demodulators, ROBA®-switch devices or similar
controls can produce disturbance which lies above the allowed
Brakes may generate further risks, among other things: limit values. For this reason it is important to read the Installation
and Operational Instructions very carefully and to keep to the
EMC directives.

Application Conditions
The catalogue values are guideline values which
Hand injuries Danger of Contact with Magnetic
have been determined in test facilities. It may be
seizure hot surfaces fields
necessary to carry out your own tests for the
intended application. When dimensioning the
Severe injury to people and damage to objects may result if: brakes, please remember that installation situations, braking
 the electromagnetic brake is used incorrectly. torque fluctuations, permitted friction work, bedding-in condition
/ conditioning of the brake linings and wear as well as general
 the electromagnetic brake is modified.
ambient conditions can all affect the given values. These
 the relevant standards for safety and / or installation factors should therefore be carefully assessed, and alignments
conditions are ignored. made accordingly.
During the risk assessment required when designing the machine
or system, the dangers involved must be evaluated and removed  Mounting dimensions and connection dimensions must be
adjusted according to the size of the brake at the place of
by taking appropriate protective measures.
installation.
To prevent injury or damage, only specialist personnel are
allowed to work on the components.  Use of the brake in extreme environmental conditions or
They must be familiar with the dimensioning, transport, outdoors, directly exposed to the weather, is not permitted.
installation, inspection of the brake equipment, initial operation,  The brakes are designed for a relative duty cycle of 50 %. A
maintenance and disposal according to the relevant standards duty cycle > 50 % leads to higher temperatures, which cause
and regulations. premature aging of the noise damping and therefore lead to
an increase in switching noises. Furthermore, the switch
Before product installation and initial operation, function of the release monitoring can be impaired. The max.
please read the Installation and Operational permitted switching frequency is 180 1/h.
Instructions carefully and observe the Safety These values are valid for intermittent periodic duty S3 50 %.
Regulations. Incorrect operation can cause injury The permitted surface temperature on the brake flange must
or damage. At the time these Installation and Operational not exceed 80 °C at a max. ambient temperature of 40 °C.
Instructions go to print, the electromagnetic brakes accord with For higher requirements on the friction work in case of
the known technical specifications and are operationally safe at EMERGENCY STOP or at temperatures of up to 90 °C on the
the time of delivery. brake flange, special friction materials and noise damping are
 Technical data and specifications (Type tags and to be used.
documentation) must be followed.  The braking torque is dependent on the current bedding-in
 The correct connection voltage must be connected according condition of the brake. Bedding in / conditioning of the friction
to the Type tag and wiring guidelines. linings is necessary.

 Check electrical components for signs of damage before  The brakes are only designed for dry running. The torque is
putting them into operation. Never bring them into contact lost if the friction surfaces come into contact with oil, grease,
with water or other fluids. water or similar substances or any other foreign bodies.

 Please observe the EN 60204-1 requirements for electrical  The surfaces of the outer components have been phosphated
connection when using in machines. manufacturer-side to form a basic corrosion protection.

Only carry out installation, maintenance and CAUTION The rotors may rust up and seize up in
repairs in a de-energized, disengaged state corrosive ambient conditions and / or after
and secure the system against inadvertent longer downtimes.
switch-on. The user is responsible for taking appropriate
countermeasures.

18/05/2022 TK/HW/SU Chr. Mayr GmbH + Co. KG

Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: +49 8341 804-0, Fax: +49 8341 804-421
Page 3 of 16 www.mayr.com, E-Mail: public.mayr@mayr.de
Installation and Operational Instructions for
ROBA-stop®-Z Type 892.101.0
Size 125 (E073 01 046 000 4 EN)

Safety Regulations
These Safety Regulations are user hints only and may not be complete!

Dimensioning Intended Use

Attention! This safety brake is intended for use in electrically operated
When dimensioning the brake, please take into consideration elevators and goods elevators. Furthermore, this brake can be
that a load torque is present when selecting the protection. used as a braking device acting on the traction sheave or the
 Load torques reduce the deceleration torque available. shaft of the traction sheave, as part of the protection device
against overspeed for the car moving in upwards direction and
 Load torques may increase the output speed: as a braking element against unintended car movement.
 during a possible processing time in the controls
 during the brake downtime Grounding Connection
When calculating the friction work, please observe that the brake The brake is designed for Protection Class I. This protection
nominal torque is subject to a tolerance. covers not only the basic insulation, but also the connection of all
conductive parts to the protective conductor (PE) on the fixed
Climate Conditions installation. If the basic insulation fails, no contact voltage will
remain. Please carry out a standardized inspection of the
The electromagnetic brake is suitable for mounting / operation protective conductor connections to all contactable metal parts!
on electromotive elevator machinery in enclosed places of
installation with an ambient temperature of between -5 °C and
+40 °C. Class of Insulation F (+155 °C)
The insulation components on the magnetic coils are
CAUTION Reduction in braking torque possible manufactured at least to class of insulation F (+155 °C).
Condensation can form on the brake and cause
a loss in braking torque: Protection
 due to fast changes in temperature (mechanical) IP10: Protection against large body surfaces and
large foreign bodies > 50 mm in diameter. No protection against
 at temperatures of around or under
water.
freezing point
(electrical) IP54: Dust-proof and protected against contact as
The user is responsible for taking appropriate
well as against water spray from any direction.
countermeasures (e.g. forced convection,
heating, drain screw).
Brake Storage
CAUTION Brake malfunction possible
 Store the brakes in a horizontal position, in dry rooms and
Condensation can form on the brake and cause
dust and vibration-free.
malfunctions:
 Relative air humidity < 50 %.
 at temperatures around or under freezing
point, the brake can freeze over and not  Temperature without major fluctuations within a range from
release any more. -5 °C up to +40 °C.
The user is responsible for taking appropriate  Do not store in direct sunlight or UV light.
countermeasures (e.g. forced convection,  Do not store aggressive, corrosive substances (solvents /
heating, drain screw). acids / lyes / salts / oils / etc.) near to the brakes.
The system function must be checked by the user after longer For longer storage of more than 2 years, special measures are
downtimes. required (please contact the manufacturer).
Storage acc. DIN EN 60721-3-1 (including the limitations /
At high temperatures and in high humidity or
additions described above): classes 1K21; 1Z1; 1B1; 1C2; 1S11;
with occurring dampness, the rotors can seize
1M11
up to the friction surfaces after longer
downtimes.
Handling
Before installation, the brake must be inspected and found to
CAUTION Temperatures of over 80 °C on the brake be in proper condition.
mounting flange can have a negative effect on The brake function must be inspected both once attachment
the switching times, the braking torque levels has taken place as well as after longer system downtimes, in
and the noise damping behavior. order to prevent the drive starting up against possibly seized
linings.

18/05/2022 TK/HW/SU Chr. Mayr GmbH + Co. KG

Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: +49 8341 804-0, Fax: +49 8341 804-421
Page 4 of 16 www.mayr.com, E-Mail: public.mayr@mayr.de
Installation and Operational Instructions for
ROBA-stop®-Z Type 892.101.0
Size 125 (E073 01 046 000 4 EN)

Safety Regulations
These Safety Regulations are user hints only and may not be complete!

User-implemented Protective Measures: EN ISO 12100 Safety of machinery – General

principles for design - Risk assessment
 Please cover moving parts to protect against injury
and risk reduction
through seizure.
DIN EN 61000-6-4 Interference emission
 Place a cover on the magnetic part to protect against injury
through high temperatures. EN 12016 Interference immunity (for elevators,
escalators and moving walkways)
 Protection circuit: When using DC-side switching, the coil
must be protected by a suitable protection circuit according
to VDE 0580, which is integrated in mayr ®-rectifiers. To Liability
protect the switching contact from consumption when using The information, guidelines and technical data in these
DC-side switching, additional protective measures are documents were up to date at the time of printing. Demands on
necessary (e.g. series connection of switching contacts). previously delivered brakes are not valid.
The switching contacts used should have a minimum contact Liability for damage and operational malfunctions will not be
opening of 3 mm and should be suitable for inductive load taken if:
switching. Please make sure on selection that the rated
- the Installation and Operational Instructions are ignored or
voltage and the rated operating current are sufficient.
neglected.
Depending on the application, the switching contact can also
be protected by other protection circuits (e.g. mayr ®-spark - the brakes are used inappropriately.
quenching unit, half-wave and bridge rectifiers), although this - the brakes are modified.
may of course then alter the switching times. - the brakes are worked on unprofessionally.
 Take precautions against freeze-up of the friction - the brakes are handled or operated incorrectly.
surfaces in high humidity and at low temperatures.
Guarantee
Standards, Directives and Regulations  The guarantee conditions correspond with
Used and To Be Applied the Chr. Mayr GmbH + Co. KG sales and delivery
conditions.
DIN VDE 0580 Electromagnetic devices and
components, general specifications  Mistakes or deficiencies are to be reported to mayr ® at
once!
2014/35/EU Low Voltage Directive
2011/65/EU RoHS II - Directive CE Identification
2015/863/EU RoHS III- Directive in accordance with the Low Voltage Directive
CSA C22.2 No. 14-2010 Industrial Control Equipment 2014/35/EU (only in case of voltages > 75 V DC)
UL 508 (Edition 17) Industrial Control Equipment and / or the RoHS Directive 2011/65/EU with
2015/863/EU,
2014/33/EU Elevator Directive and the Elevator Directive 2014/33/EU
EN 81-20 Safety rules for the construction and (with the ID number of the respective inspection authority, for
installation of lifts – type examination tested brakes only)
Part 20: Passenger and goods
passenger lifts Conformity Markings
EN 81-50 Safety rules for the construction and in terms of the Canadian and American approval
installation of lifts - Examinations and
tests – Part 50: Design rules,
calculations, examinations and tests of
lift components

Marking
mayr ® components are clearly marked and described on the Type tag:

Product name Serial number Article number

Size/Type Voltage Power Braking torque DataMatrix code

18/05/2022 TK/HW/SU Chr. Mayr GmbH + Co. KG

Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: +49 8341 804-0, Fax: +49 8341 804-421
Page 5 of 16 www.mayr.com, E-Mail: public.mayr@mayr.de
Installation and Operational Instructions for
ROBA-stop®-Z Type 892.101.0
Size 125 (E073 01 046 000 4 EN)

18.3 11 23 18.5 18.4 21/22 20 18.1 18.3

18.2 18.7 18.9/18.10 18.6 9 19 18.6 18.7 18.8/18.11 18.2

Fig. 1 Fig. 2 Fig. 3

11.4 11.3
Installation dimension
115 +1 mm 14 11.2
24 4
20 11.1
7 3
21/22 2
2.1 5 11.5
1.1

1.1 Fig. 5
12
1
Insertion position for Insertion position for
13 brake circuit 2 inspection brake circuit 1 inspection
1.2 Item 10

15
5

2 6

8 b b 14

Air gap “a”

Fig. 4

Fig. 6 Fig. 7

18/05/2022 TK/HW/SU Chr. Mayr GmbH + Co. KG

Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: +49 8341 804-0, Fax: +49 8341 804-421
Page 6 of 16 www.mayr.com, E-Mail: public.mayr@mayr.de
Installation and Operational Instructions for
ROBA-stop®-Z Type 892.101.0
Size 125 (E073 01 046 000 4 EN)

Parts List (Only use mayr  original parts)

Item Name Pcs.
1 Hub 1
1.1 O-ring D60 x 3 2
1.2 Set screw M6 x 10 1
2 Brake body 1
2.1 Magnetic coil 1
3 Cap screw M8 x 85 3
4 Washer D16 / 8.4 x 1.6 3
5 Rotor 1 1
6 Rotor 2 1
7 Distance bolt 3
8 Thrust spring D15.5 / 2.8 x 39.5 4
9 Cable 2 x AWG18 1
10 Reference gauge 2
11 Release monitoring (page 12) 1
11.1 Microswitch 1
11.2 Hexagon head screw M5 x 20 1
11.3 Hexagon nut M5 1
11.4 Spring washer A5 1
11.5 Cap screw M4 x 8 2
12 1)
Hub 1
13 Elastomeric element 1
14 Armature disk 1
15 Brake plate 1
16 2)
Headless screw M8 x 30 2
17 2) Plastic tube D10 / 8 x 14 2
18 3) Hand release 1
18.1 Switch bracket A 1
18.2 Switch bracket B 2
18.3 Cap screw M8 x 14 4
18.4 Hand release rod 1
18.5 Hexagon nut M16 1
18.6 Headless screw M8 x 30 2
18.7 Flat headed screw M8 x 10 2
18.8 Thrust spring holder 1
18.9 Cap screw M6 x 25 1
18.10 Washer A6.4 1
18.11 Thrust spring D15.5 / 2.5 x 28 1
19 Noise damping 4
20 Grounding strand 1
21 Cap screw M4 x 8 2
22 Contact washer M4 2
23 4) Hexagon nut M8 1
24 Type tag 1
We reserve the right to make dimensional and constructional alterations!
1)
On article number 8253118, the hub is not included in the standard scope of delivery.
2)
Items 16 and 17 are included loose in delivery and are not shown in the Figure.
3)
On article number 8292346, the hand release is not included in the standard scope of delivery.
4)
Plastic nut, serves only as transportation lock.

18/05/2022 TK/HW/SU Chr. Mayr GmbH + Co. KG

Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: +49 8341 804-0, Fax: +49 8341 804-421
Page 7 of 16 www.mayr.com, E-Mail: public.mayr@mayr.de
Installation and Operational Instructions for
ROBA-stop®-Z Type 892.101.0
Size 125 (E073 01 046 000 4 EN)

Table 1: Technical Data

Article number 8227821 8253118 8292346
Nominal voltage 90 V 90 V 55 V
Overexcitation voltage 180 V 180 V 110 V
Coil power (nominal power at 20°C) 76 W 76 W 71 W
Coil power on overexcitation 303 W 303 W 284 W
Overexcitation time span 1s
Nominal braking torque (+60 %) 100 (2 x 50) Nm
Rotor thickness, new condition 10.5 mm
Nominal air gap “a” total (braked) 0.5 +0.25 mm
Limit air gap “a” for rotor replacement 1.0 mm
Inspection air gap “b” released, per single circuit min. 0.15 mm
Tightening torque Item 1.2 3 Nm
Tightening torque Item 3 24 Nm
Tightening torque Item 16 8.5 Nm
Tightening torque Item 18.3 24 Nm
Tightening torque Item 18.6 8.5 Nm
Tightening torque Item 18.7 8.5 Nm
Tightening torque Item 18.9 10 Nm
Max. Speed 2250 rpm
Max. permitted friction work for both rotors at a speed of 1800 rpm 5000 J
Weight 11.4 kg

Table 2: Switching Times

Attraction t2 50 ms
Drop-out t0 (DC): 25 ms
Drop-out t 50 (DC) 5): 35 ms
Drop-out t 90 (DC) 5): 40 ms
Drop-out t11 AC 180 ms
Drop-out t1 AC 6) 340 ms

5)
Referring to the nominal braking torque
6)
Referring to the effective braking torque
The stated switching times can only be achieved using the respective correct electrical wiring. This also refers to the
protection circuit for brake control and the response delay times of all control components. If the brake is operated using
overexcitation, the respective switch-on and switch-off times for overexcitation must be taken into account.
The use of varistors for spark quenching increases the DC-side switching times.

18/05/2022 TK/HW/SU Chr. Mayr GmbH + Co. KG

Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: +49 8341 804-0, Fax: +49 8341 804-421
Page 8 of 16 www.mayr.com, E-Mail: public.mayr@mayr.de
Installation and Operational Instructions for
ROBA-stop®-Z Type 892.101.0
Size 125 (E073 01 046 000 4 EN)

Application Installation Conditions

 ROBA-stop®-Z brake for use as a holding brake with  The eccentricity of the shaft end in relation to the mounting
occasional EMERGENCY STOP braking actions (max. 10 pitch circle must not exceed 0.2 mm.
per day).  The positional tolerance of the threads for the cap screws (3)
 The max. permitted speed and friction work (see Technical must not exceed 0.2 mm.
Data) must be observed.  The axial run-out deviation of the screw-on surface to the
shaft must not exceed the permitted axial run-out tolerance of
0.05 mm acc. DIN 42955 R.
Design The reference diameter is the pitch circle diameter for
securement of the brakes.
The ROBA-stop®-Z brake is a spring applied, electromagnetically Larger deviations can lead to a drop in torque, to continuous
releasing dual circuit safety brake, which applies a defined grinding on the rotors and to overheating.
braking effect after the voltage is switched off or after a voltage
failure.  The fit tolerance of the shaft must be selected so that the hub
This brake is combined with a positive-locking, flexible coupling toothing (1) is not widened. Widening of the toothing leads to
(ROBA®-ES coupling) for connecting two shafts whilst the rotors (5 and 6) jamming on the hub (1) and therefore to
compensating for shaft misalignments. brake malfunctions.
The ROBA®-ES coupling compensates for axial, radial and Recommended fit tolerance for the shaft: k6
angular shaft misalignments. The max. permitted joining temperature of 150 °C must not be
exceeded.
 The O-rings (1.1) on the hub (1) must be lightly greased.
Function  The rotors (5 and 6) and the brake surfaces must be oil and
The ROBA-stop®-Z brake is a spring applied, electromagnetic grease-free.
safety brake.  A suitable counter friction surface (steel or cast iron) must be
used. Sharp-edged interruptions on the friction surfaces must
Spring applied function (brake): be avoided. Recommended surface quality in the area of the
In de-energized condition, thrust springs (8) press against the friction surface Ra = 0.8 – 1.6 µm. The mounting surface must
armature disk (14). Rotor 2 (Item 6) is held between the armature be turned. The surface must be bare or FE-phosphated (layer
disk (14) and the brake plate (15), rotor 1 (Item 5) is held between thickness approx. 0.5 µm) without oil.
the brake body (2) and the machine wall via frictional locking. If corrosion protection is applied, the device must be
The braking torque is introduced into the drive line via the inspected for possible effects on the braking torque.
toothing of the rotors (5 and 6) and the hub (1). In particular customer-side mounting surfaces made of
grey cast iron are to be rubbed down additionally with
Electromagnetic function (release): sandpaper (grain  60 to 100).
Due to the magnetic force of the coil in the brake body (2), the
 The toothings of the hub (1) and the rotors (5 and 6) must not
armature disk (14) is attracted against the spring pressure (8) to
be oiled or greased.
the brake body (2). The brake is released and the brake rotors (5
and 6) with the hub (1) can rotate freely.  Friction value-increasing surface treatments are not
permitted.
Safety brakes:  Please abstain from using cleaning agents containing
The ROBA-stop®-Z brake brakes reliably solvents, as they could affect the friction material.
and safely in the event of a power switch-off, a power failure or an
EMERGENCY STOP.

Scope of Delivery / State of Delivery

The ROBA-stop®-Z brake is pre-assembled.
On brake article number 8253118, the hub (12) is not included in
the standard scope of delivery.
Brake article number 8292346 is designed without hand release
(18).
The release monitoring (11) device is installed and set
manufacturer-side.
The brakes are set manufacturer-side to the braking torque
stipulated on order.
Please check the scope of delivery according to the Parts List as
well as the state of delivery immediately after receiving the goods.
mayr ® will take no responsibility for belated complaints.
Please report transport damage immediately to the deliverer.
Please report incomplete delivery and obvious defects
immediately to the manufacturer.

18/05/2022 TK/HW/SU Chr. Mayr GmbH + Co. KG

Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: +49 8341 804-0, Fax: +49 8341 804-421
Page 9 of 16 www.mayr.com, E-Mail: public.mayr@mayr.de
Installation and Operational Instructions for
ROBA-stop®-Z Type 892.101.0
Size 125 (E073 01 046 000 4 EN)

Installation
All the screws (except the cap screw Item 21) 20. Mount plastic hoses (17) onto both headless screws (16) in
and the set screws mounted by the customer order to dampen vibration noises.
must be tightened using the tightening torque 21. Insert the elastomeric element (13) in the claws of the hub
stated in Table 1. (1).
We recommend that you secure the screws 22. Mount the hub (12) onto the motor shaft with the inserted
using Loctite 243. key and bring it into the correct axial position (installation
1. Remove all 3 hexagon nuts (Item 23 / transportation lock) dimension 115 +1 mm, see Fig. 4).
and remove the brake plate (15) from the brake body (2). 23. Establish the positive locking between the hub (12) and the
2. Mount the hub (1) onto the shaft with inserted key and elastomeric element (13).
secure it axially. Due to the pre-tension on the flexible elastomeric element
Axial securement takes place using the set screw (1.2), (13), an axial installation force is required when joining both
which presses onto the customer-side key. hubs (1 and 12) (Fig. 5). The force required can be reduced
by lightly greasing the elastomeric element (13).
3. Lightly grease the first O-ring (1.1) and insert it into the hub
(1) groove nearest to the machine wall.
4. Push the rotor 1 (Item 5) over the inserted O-ring (1.1) onto Use PU-compatible lubricants
the hub (1) by hand using light pressure (the rotor collar (e. g. Vaseline or HP 222)!
should be facing away from the machine wall).
Make sure that the toothing moves easily.
5. Lightly grease the second O-ring (1.1) and insert it into the After joining both hubs, no axial pressure must
other (not occupied) hub (1) groove. be placed on the elastomeric element (13).
6. Push brake body (2) over the hub (1) and insert it in the Keep to the installation dimension 115 +1 mm,
gear housing. see Fig. 4.
7. Push the rotor 2 (6) over the O-ring (1.1) onto the hub (1)
by hand using light pressure (the rotor collar should be 24. Check air gap “a” (Fig. 4).
facing the machine wall). The nominal air gap acc. Table 1 must be given.
Make sure that the toothing moves easily. 25. Check the air gap single circuits "b" (Fig. 4) on rotors 1
8. Insert the cap screws (3) including the washers (4) in the and 2.
distance bolts (7) through the brake plate (15). The respective minimal air gap acc. Table 1 must be given.
9. Secure the brake evenly all around using the cap screws
(3) with a torque wrench.
10. Attach the grounding strand (20) onto the brake body (2)
Adjustment
using the cap screw (21) and the contact washer (22). The brakes are equipped manufacturer-side with
To do this, the contact washer (22) must be inserted the respective springs for the braking torque
between cable lug and brake body (2). stated on the Type tag (24). Adjustment is not
11. Attach the grounding strand (20) onto the brake plate (15) necessary. Adaptions or modifications are not
using the cap screw (21) and the contact washer (22). To permitted as a rule. This rule also applies to the manufacturer-
do this, the contact washer (22) must be inserted between side adjusted noise damping. The switches are also adjusted
cable lug and brake plate (15). manufacturer-side. Despite great care during the manufacturer-
Steps 12 to 20 do not apply for article number 8292346. side adjustment, re-adjustment might be necessary after
installation due to transportation and handling. Furthermore,
12. Screw the headless screws (18.6) on both sides into the such switches cannot be considered fail-safe.
armature disk (14). Please also observe the section ‘Release Monitoring’.
13. Attach both switch brackets B (18.2) in the correct position
onto the brake body (2) using the flat headed screws (18.7).
14. Secure the thrust spring holder (18.8) onto the brake body Noise Damping (Item 19 / Fig. 2)
(2) using the cap screw (18.9) and the washer (18.10), so
that the pin of the thrust spring holder (18.8) points in the The noise damping was set and adjusted
direction of the knob of switch bracket B (18.2). manufacturer-side. However, this component is
subject to aging dependent on the application
15. Tilt switch bracket B (18.2) and join the thrust spring (18.11)
or operating conditions (torque adjustment,
between the thrust spring holder (18.8) and switch bracket
switching frequency, ambient conditions,
B (18.2).
system vibrations etc.).
16. Screw switch bracket A (18.1) onto switch bracket B (18.2) Replacing the damping element is only
on both sides using the cap screws (18.3). permitted at the mayr ® site of manufacture.
17. Screw the hexagon nut (18.5) up to contact on the thread
end onto the hand release rod (18.4).
18. Screw the hand release rod (18.4) into switch bracket A
(18.1) and counter the hexagon nut (18.5) with an open-end
wrench.
19. Screw both headless screws (Item 16 / not shown) as
contact for the hand release into the gear housing.

18/05/2022 TK/HW/SU Chr. Mayr GmbH + Co. KG

Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: +49 8341 804-0, Fax: +49 8341 804-421
Page 10 of 16 www.mayr.com, E-Mail: public.mayr@mayr.de
Installation and Operational Instructions for
ROBA-stop®-Z Type 892.101.0
Size 125 (E073 01 046 000 4 EN)

Electrical Connection and Wiring Magnetic Field Removal

In safety applications, the rules for risk minimisation and error AC-side switching
avoidance (e.g. redundance, diversity, resistance, monitoring etc.) The power circuit is interrupted
must be observed during electrical activation. in front of the rectifier. The
The power is connected using a 2-core cable (9). magnetic field slowly reduces.
This delays the rise in braking
The brake must only be operated with torque.
overexcitation (see Technical Data).
When switching times are not
important, please switch AC-
DC current is necessary for operation of the brake. The coil side, as no protective
nominal voltage is indicated on the Type tag as well as on the measures are necessary for
brake body and is designed according to the DIN IEC 60038 coil and switching contacts.
(± 10 % tolerance). The brake must only be operated with Coil
overexcitation (e.g. using a ROBA®-switch or -multiswitch fast
acting rectifier or phase demodulator). The connection
possibilities can vary dependent on the brake equipment. Please
follow the exact connections according to the Wiring Diagram.
The manufacturer and the user must observe the applicable F1: external fuse
regulations and standards (e.g. DIN EN 60204-1 and DIN VDE
0580). Their observance must be guaranteed and double- AC-side switching means low-noise switching; however, the
checked! brake engagement time is longer (approx. 6-10 times longer than
with DC-side disconnection), use for non-critical braking times.
Grounding Connection
DC-side switching
The brake is designed for Protection Class I. This protection
covers therefore not only the basic insulation, but also the The power circuit is interrupted
connection of all conductive parts to the protective conductor (PE) between the rectifier and the
on the fixed installation. If the basic insulation fails, no contact coil as well as mains-side. The
voltage will remain. Please carry out a standardized inspection of magnetic field reduces
the protective conductor connections to all contactable metal extremely quickly. This causes
parts! a quick rise in braking torque.

Device Fuses When switching DC-side, high

voltage peaks are produced in
To protect against damage from short circuits, please add the coil, which can lead to wear
suitable device fuses to the mains cable. on the switching contacts from
Coil sparks and to destruction of the
Switching Behavior insulation.
The reliable operational behavior of a brake is to a large extent
dependent on the switching mode used. Furthermore, the
switching times are influenced by the temperature and the air gap
between the armature disk and the coil carrier (dependent on the F1: external fuse
wear condition of the linings).
DC-side switching means short brake engagement times (e.g.
Magnetic Field Build-up for EMERGENCY STOP operation); however, louder switching
noises.
When the voltage is switched on, a magnetic field is built up in the
brake coil, which attracts the armature disk to the coil carrier and
releases the brake.
Protection Circuit
When using DC-side switching, the coil must be protected by a
suitable protection circuit according to VDE 0580, which is
integrated in mayr ®-rectifiers. To protect the switching contact
from consumption when using DC-side switching, additional
protective measures are necessary (e.g. series connection of
switching contacts). The switching contacts used should have a
minimum contact opening of 3 mm and should be suitable for
inductive load switching. Please make sure on selection that the
rated voltage and the rated operating current are sufficient.
Depending on the application, the switching contact can also be
protected by other protection circuits (e.g. mayr ®-spark quenching
unit, half-wave and bridge rectifiers), although this may of course
then alter the switching times.

18/05/2022 TK/HW/SU Chr. Mayr GmbH + Co. KG

Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: +49 8341 804-0, Fax: +49 8341 804-421
Page 11 of 16 www.mayr.com, E-Mail: public.mayr@mayr.de
Installation and Operational Instructions for
ROBA-stop®-Z Type 892.101.0
Size 125 (E073 01 046 000 4 EN)

Permitted Shaft Misalignments Shaft Alignment

ROBA®-ES coupling compensates for radial, axial and angular Exact alignment of the shafts improves the running smoothness
shaft misalignments (Fig. 3) without losing its backlash-free of the coupling substantially, reduces the load on the shaft
function. However, the permitted shaft misalignments indicated in bearings and increases the coupling service lifetime.
Table 3 must not simultaneously reach their maximum value. We recommend alignment of the coupling using a dial gauge or
If more than one kind of misalignment takes place simultaneously, special laser on drives operating at very high speeds.
they influence each other. This means that the permitted
misalignment values are dependent on one another, see Fig. 4.
The sum total of the actual misalignments in percent of the
maximum value must not exceed 100 %.

Δ Kr [%] Radial misalignment

The permitted misalignment values given in Table 3 refer to
coupling operation at nominal torque, an ambient temperature of
+30 °C.
If the coupling is operated in other or more extreme operating
Δ Kw [%]
conditions, please contact the manufacturers. Angular misalignment

Table 3
Max. Permitted Shaft Misalignments
ΔKa ± 1.5 mm

ΔKr 0.11 mm

ΔKw 0.9 °

Δ Ka [%] Axial displacement

Fig. 9

Axial Radial Angular

displacement misalignment misalignment

Fig. 8

18/05/2022 TK/HW/SU Chr. Mayr GmbH + Co. KG

Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: +49 8341 804-0, Fax: +49 8341 804-421
Page 12 of 16 www.mayr.com, E-Mail: public.mayr@mayr.de
Installation and Operational Instructions for
ROBA-stop®-Z Type 892.101.0
Size 125 (E073 01 046 000 4 EN)

Braking Torque Dual Circuit Brake Functional Inspection

The (nominal) braking torque is the torque effective in the shaft The ROBA-stop®–Z brake is equipped with a double safety
train on slipping brakes, with a sliding speed of 1 m/s referring to (redundant) braking system. If one brake circuit fails, min. 50 % of
the mean friction radius. the braking torque remain. The single brake circuit inspection is
The brake is loaded statically when used as a service brake and carried out using the reference gauges (10) included in delivery.
loaded dynamically in EMERGENCY STOP operation.
Respectively, there are different speed values for the friction DANGER Should the load begin to move after tilting the
material, which in practice also leads to different friction values feeler gauges (10) or should it fail to react to
and therefore braking torques. Amongst other things, the braking the braking procedure, the reference gauges
torque is dependent on the respective quality / condition of the must be pivoted back and removed
friction surfaces (conditioning). Therefore, bedding in of the brake immediately.
linings on newly installed brakes or on rotor replacement when The dual circuit braking function is not
mounted is required, taking into account the permitted loads: The guaranteed.
following applies as a reference value for the bedding in of new Shut down the system, lower and secure the
brake linings. The load in new condition may not be more than 50 load, remove and inspect the brake.
% of the max. friction work, acc. Technical Data. This process is Please observe the accident prevention
to be carried out at reduced speed, approx. 30 % of the operating regulations.
speed.
If the bedding in should take place under works-specific Remove the reference gauges (ideally attached to the motor or
conditions, we ask you to contact us, so that we can provide the the gearbox).
appropriate parameters.
Friction materials develop their optimum effect only under speed Inspection brake circuit 1 (mounting-side, see Fig. 1):
at the appropriate contact pressure, as continuous regeneration 1. Push both reference gauges, 180° offset to each other, with
of the friction surface then takes place (torque consistency). the flattened section between the brake body (2) and the
Permanent grinding of the rotors can lead to overheating / machine wall.
damage to the brake linings, and therefore to a drop in braking Set up the reference gauges at 90° (tilt) and hold in this
torque. position (no spring force on rotor 1 (Item 5)).
Furthermore, friction materials are subject to aging, which is also
influenced, among other things, by higher temperatures and other 2. Energize the brake and put the drive into operation.
ambient influences. We recommend regular inspection of the 3. De-energize the brake (= EMERGENCY STOP) and inspect
braking torque (1 x per year) including the respective dynamic the stopping distance.
braking actions as a refresher. 4. Turn the flat sections of the reference gauges once more
and remove them from the brake.

Brake Inspection (before brake initial operation) Inspection brake circuit 2 (brake plate-side, see Fig. 1):
 Air gaps inspection (Fig. 4) 1. Push both reference gauges, 180° offset to each other, with
Measure the air gap “a” (brake de-energized) several times the flattened section between the armature disk (14) and the
on the circumference. brake plate (15). Set up the reference gauges at 90°
The nominal air gap acc. Table 1 must be given. (tilt) and hold in this position (no spring force on rotor 2 (Item
Measure the min. individual air gap "b" (brake energized) of 6)).
brake circuit 1 (inside) and brake circuit 2 (outside) several
times on the circumference. 2. Energize the brake and put the drive into operation.
The respective minimal air gap acc. Table 1 must be given. 3. De-energize the brake (= EMERGENCY STOP) and inspect
 Braking torque inspection: the stopping distance.
Please compare the requested braking torque with the 4. Turn the flat sections of the reference gauges once more
torque stated and remove them from the brake.
on the Type tag (24).
 Release function inspection Attach the reference gauges to the motor or gearbox again.
by energizing the brake.
 Switch function inspection of the release monitoring
with microswitch (NO contact)
Brake de-energized  Signal “OFF”
Brake energized  Signal “ON”
 Hand release functional inspection
By deflecting the hand release (18) manually, the friction
linings are relieved. The brake is free but for a residual
torque of max. 8 %.

When actuating the hand release (18), a

switching signal of the release monitoring
device (11) cannot be guaranteed.

18/05/2022 TK/HW/SU Chr. Mayr GmbH + Co. KG

Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: +49 8341 804-0, Fax: +49 8341 804-421
Page 13 of 16 www.mayr.com, E-Mail: public.mayr@mayr.de
Installation and Operational Instructions for
ROBA-stop®-Z Type 892.101.0
Size 125 (E073 01 046 000 4 EN)

Release Monitoring
The brakes are supplied with manufacturer-side installed and Customer-side Inspection after Attachment
adjusted release monitoring device.
For customer-side connection as NO contact.
The microswitch (11.1) emits a signal for every brake condition
change: "brake opened or brake closed" Brake de-energized  Signal "OFF",
The customer is responsible for a signal evaluation of both Brake energized  Signal “ON”
conditions. For customer-side connection as NC contact.
From the point at which the brake is energized, a time span of Brake de-energized  Signal “ON”,
three times the separation time must pass before the switch
signal on the release monitoring is evaluated. Brake energized  Signal “OFF”

11.4 11.3
Microswitches cannot be guaranteed fail-safe.
Therefore, please ensure appropriate access
14 11.2 for replacement or adjustment.
The switching contacts are designed so that
20 11.1 they can be used for both small switching
powers and medium ones. However, after
21/22 2 switching a medium switching power, small
switching powers are no longer reliably
possible.
5 11.5 In order to switch inductive, capacitive and non-
linear loads, please use the appropriate
Fig. 10 protection circuit to protect against electric arcs
and unpermitted loads!
Function
When the magnetic coil (2.1) is energized in the brake body (2),
the armature disk (14) is attracted to the brake body (2), the
microswitch (11.1) emits a signal, the brake is released.

When actuating the hand release (18), a

switching signal of the release monitoring
device (11) cannot be guaranteed.

Microswitch Wiring Diagram:

NC contact
Grey connection
Connection when
2 brake closed

COM contact 1
Black connection 4
NO contact
Blue connection
Connection when
brake released

Microswitch Specification
Characteristic values for 250 V~ / 3 A
measurement:
Minimum switching power: 12 V, 10 mA DC-12
Recommended switching 24 V, 10...50 mA
power: DC-12
for maximum lifetime DC-13 with freewheeling
and reliability diode!
Usage category acc. IEC 60947-5-1:
DC-12 (resistance load), DC-13 (inductive load)

18/05/2022 TK/HW/SU Chr. Mayr GmbH + Co. KG

Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: +49 8341 804-0, Fax: +49 8341 804-421
Page 14 of 16 www.mayr.com, E-Mail: public.mayr@mayr.de
Installation and Operational Instructions for
ROBA-stop®-Z Type 892.101.0
Size 125 (E073 01 046 000 4 EN)

Maintenance Replacing the Rotors (5 and 6)

ROBA-stop®–Z brakes are mainly maintenance-free. The friction Before Replacing the Rotors
lining pairing is robust and wear-resistant. This ensures a  Cleaning of the brake.
particularly long service lifetime of the brake.
However, the friction lining is subject to operational wear on
frequent EMERGENCY STOP braking actions. Normally, such Please observe the section “Cleaning the
occurrences are recorded and saved by the elevator control, Brake”, see below.
or they require the intervention of qualified personnel. When
carrying out this maintenance work (especially when taking DIN
EN 13015 Appendix A into account), the causes of the  Measure the rotor thickness “new condition” (nominal
malfunction must be determined, assessed and removed by dimension 8 -0.05 mm).
specialist personnel. Causal events such as the air gap can be Rotor (5 and 6) replacement is carried out by following the
checked and respective measures can be taken. Installation section (page 9) backwards.
The brakes on the elevator system must be maintained and
repaired by a specialist employee, taking into consideration the DANGER
type and intensity of use of the system. The drive brake must be load-free on hoist
The following inspections / tests are to be conducted within the drives. Otherwise there is a danger of load
scope of the defined elevator maintenance interval during crashes!
maintenance and repairs.
1. Visual inspection
 Inspection of condition in accordance with the regulations
 Brake rotors: in particular the exterior appearance of the Information on the Components
brake surfaces The friction material contains different inorganic and organic
- wear compounds, which are integrated into a system of hardened
- free of oil / lubricants binding agents and fibers.
- sticking of linings
Possible hazards:
2. Tightening torque inspection of the fixing screws on the No potential dangers have been recognized so far when the
brakes. If the brake fixing screws are covered with sealing brake is used according to its intended purpose. When grinding in
lacquer, a visual inspection for damage of the sealing is the brake linings (new condition) and also in case of
sufficient. EMERGENCY STOP braking actions, functional wear can occur
3. Inspection of the air gap – braked (wear on the friction linings); on open brake designs, fine dust can
4. Inspection of toothing backlash from the splined motor shaft be emitted.
to the rotors (5 and 6)
Max. permitted toothing backlash 0.3° Classification: Hazardous property
Attention: H-classification: H372
5. Running noise (brake rotors) during operation
Attention: Permanent grinding of the rotors can lead to
overheating / damage to the brake linings, and therefore to a Protective measures and rules of behavior:
drop in braking torque. If such indications are present, it is Do not inhale dusts.
essential that the braking torque is checked and the rotors Vacuum the dusts at the point of origin (tested suction devices,
replaced if required independent of the inspection or the tested filters acc. DIN EN 60335-2-69 for dust classes H;
determined wear value! maintenance of the suction devices and filter replacement at
regular intervals).
6. Braking torque or delay inspection (individual brake circuits)
If local dust suction is not possible or is insufficient, the entire
at least once per year (within the scope of the maintenance /
work area must be ventilated using appropriate technology.
main inspection)
Additional information:
In order to inspect the wear condition of the This friction lining (asbestos free) is not a dangerous product in
rotors (5 and 6), please measure the air gap terms of the EU Directive.
"a", see Fig. 4.
If the brake limit air gap (1.0 mm) has been
reached, meaning that the friction linings are Cleaning the Brake
worn down, the braking torque is lost and the
rotors (5 and 6) must be replaced.
Brake de-installation is carried out by following Do not clean the brake using compressed air,
the instructions in the section Installation (page brushes or similar devices!
9) backwards.
 Wear safety gloves / safety goggles.
7. Hand release function inspection.  Use a suction system or wet towels to clean off the brake
dust.
Automatic resetting of the hand release to its  Do not inhale brake dust.
initial position (after actuation) must be given.  In case of dust formation, a dust mask FFP 2 is
recommended.

18/05/2022 TK/HW/SU Chr. Mayr GmbH + Co. KG

Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: +49 8341 804-0, Fax: +49 8341 804-421
Page 15 of 16 www.mayr.com, E-Mail: public.mayr@mayr.de
Installation and Operational Instructions for
ROBA-stop®-Z Type 892.101.0
Size 125 (E073 01 046 000 4 EN)

Disposal
Our electromagnetic brake components must be disposed of Guidelines on the WEEE Directive 2012/19/EU
separately as they consist of different materials. Please also Avoidance of waste from electrical and electronic devices and the
observe the relevant authority regulations. Code numbers may reduction of such waste through recycling.
vary according to the disassembling process (metal, plastic and Our electromagnetic products (brakes, clutches) as well as the
cables). components required to control them (rectifiers) are frequently
used in electrical and electronic devices within the appropriate
Electronic Components (Rectifier / Switch): area of application of WEEE, independent of the applicable
Products which have not been disassembled can be disposed of product categories.
under Code No. 160214 (mixed materials) or components under The stated products do not fall within the area of application of
Code No. 160216, or can be disposed of by a certified disposal this Directive. They have been classified as electromagnetic /
firm. electronic components (VDE 0580) or as electronic equipment
Brake bodies made of steel with coil/cable and all other steel (DIN EN 50178), and have been determined for installation in
components: devices for "use in accordance with the intended purpose". Only
Steel scrap (Code No. 160117) products which are to be viewed as devices in terms of the
Directive and not as parts or components are subject to
All aluminum components: registration obligations.
Non-ferrous metals (Code No. 160118)
Brake rotor (steel or aluminum pads with friction linings):
Brake linings (Code No. 160112)
Seals, O-rings, V-seals, elastomers, terminal boxes (PVC):
Plastic (Code No. 160119)

Malfunctions / Breakdowns:

Malfunction Possible Causes Solutions

 Incorrect voltage on rectifier  Apply correct voltage
 Rectifier failure  Replace rectifier
Brake does not release
 Air gap too large (worn rotors)  Replace rotors
 Coil interrupted  Replace brake

Brake engagement delayed

 Brake is switched AC-side  Switch DC-side
on EMERGENCY STOP

Release monitoring does not  Brake does not release  Solution as above
switch  Defective microswitch  Replace the microswitch (manufacturer-side)

18/05/2022 TK/HW/SU Chr. Mayr GmbH + Co. KG

Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: +49 8341 804-0, Fax: +49 8341 804-421
Page 16 of 16 www.mayr.com, E-Mail: public.mayr@mayr.de
Installation and Operational Instructions for
ROBA-stop®-Z Type 892.101.0
Size 125 (E073 01 046 000 4 EN)

Translation of the Original Operational Instructions

Design according to
Drawing number: E073 01 046 000 1 10 Article number: 8227821
Drawing number: E073 01 046 000 1 11 Article number: 8253118 (without hub (12))
Drawing number: E073 01 046 000 1 12 Article number: 8292346 (without hand release (18))

Please read these Operational Instructions carefully and follow them accordingly!
Ignoring these Instructions can lead to lethal accidents, malfunctions, brake failure and damage to other parts.
These Installation and Operational Instructions (I + O) are part of the brake delivery.
Please keep them handy and near to the brake at all times.

Contents: Safety and Guideline Signs

Page 1: - Contents DANGER
- Safety and Guideline Signs
Immediate and impending danger, which can
Page 2: - Guidelines on EU Directives lead to severe physical injuries or to death.

Page 3: - Safety Regulations

Page 4: - Safety Regulations
CAUTION
Page 5: - Safety Regulations
Danger of injury to personnel and
Page 6: - Brake Illustrations damage to machines.
Page 7: - Parts List
Page 8: - Technical Data
- Switching Times
Please Observe!
Page 9: - Application Guidelines on important points.
- Design
- Function
- Scope of Delivery / State of Delivery
- Installation Conditions
Page 10: - Installation
- Adjustment
- Noise Damping
Page 11: - Electrical Connection and Wiring
Page 12: - Permitted Shaft Misalignments
- Shaft Alignment
Page 13: - Braking Torque
- Brake Inspection
- Dual Circuit Brake Functional Inspection
Page 14: - Release Monitoring
Page 15: - Maintenance
- Replacing the Rotors
- Information on the Components
- Cleaning the Brake
Page 16: - Disposal
- Malfunctions / Breakdowns

18/05/2022 TK/HW/SU Chr. Mayr GmbH + Co. KG

Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: +49 8341 804-0, Fax: +49 8341 804-421
Page 1 of 16 www.mayr.com, E-Mail: public.mayr@mayr.de
Installation and Operational Instructions for
ROBA-stop®-Z Type 892.101.0
Size 125 (E073 01 046 000 4 EN)

Guidelines on the Declaration of Conformity

A conformity evaluation has been carried out for the product (electromagnetic safety brake) in terms of the EU Low
Voltage Directive 2014/35/EU and the RoHS 2011/65/EU with 2015/863/EU. The Declaration of Conformity is laid out in
writing in a separate document and can be requested if required.
Guidelines on the EMC Directive 2014/30/EU
The product cannot be operated independently according to the EMC directive.
Due to their passive state, brakes are also non-critical equipment according to the EMC.
Only after integration of the product into an overall system can this be evaluated in terms of the EMC.
For electronic equipment, the evaluation has been verified for the individual product in laboratory conditions, but not in the
overall system.
Guidelines on the Machinery Directive 2006/42/EC
The product is a component for installation into machines according to the Machinery Directive 2006/42/EC.
The brakes can fulfil the specifications for safety-related applications in coordination with other elements.
The type and scope of the required measures result from the machine risk analysis. The brake then becomes a machine
component and the machine manufacturer assesses the conformity of the safety device to the directive.
It is forbidden to start use of the product until you have ensured that the machine accords with the regulations stated in the
directive.
Guidelines on the EU Directive 2011/65/EU (RoHS II) with 2015/863/EU (RoHS III – from 22 July 2019)
These restrict the use of certain hazardous substances in electrical and electronic devices as well as in products /
components (category 11), the proper operation of which is dependent on electric currents and electromagnetic fields.
Our electromagnetic products / components fulfill the requirements laid down in the RoHS Directive(s), taking
into account the valid exceptions (according to Appendix III and IV RoHS (2011/65/EU) with delegated Directives
(EU) 2018/739-741 from 01.03.2018 for Category 11 – until 21 July 2024) and comply with the RoHS.
Guidelines on the ATEX Directive
Without a conformity evaluation, this product is not suitable for use in areas where there is a high danger of explosion.
For application of this product in areas where there is a high danger of explosion, it must be classified and marked
according to Directive 2014/34/EU.
Guidelines on the REACH Regulation (EC) No. 1907/2006
of the European Parliament and of the Council concerning the Registration, Evaluation, Authorization and Restriction of
Chemicals (REACH). This regulation governs the manufacture, placing on the market and use of chemical substances in
preparations and, under certain conditions, also of substances in finished products.
mayr ® power transmission exclusively manufactures products (articles: overload clutches, shaft couplings,
electromagnetic brakes / clutches, permanent magnet motors and the appropriate control modules / rectifiers) in
accordance with the definition in Article 3 of the REACH Regulation.
mayr ® power transmission is aware of its responsibility towards the environment and society. As a matter of precaution,
we pay attention to particularly critical substances in the supply chain and strive to avoid using any such substances
completely or to replace them in the near future.
In compliance with Article 33 of the REACH Regulation, we would like to inform you that in our overload clutches and shaft
couplings, electromagnetic brakes / clutches as well as permanent magnet motors, subcomponents with a lead content of
> 0.1% are or may be used. These are manufactured from raw materials such as machining steel / copper alloys (e.g.
brass, bronze) or aluminum alloys.
Besides high-melting-point (HMP) solders (electronics), this also affects integrated machine elements as well as standard
parts (screws / nuts / set screws / pins / etc.) among others, provided that the relevant standards allow this.
For example, lead can occur as an alloying element with more than 0.1 mass percent, based on the respective total mass,
in screws and set screws of the following property classes: 4.6, 4.8, 5.8, 6.8, 04, 4, 5, 6, 14H, 17H, 22H, 33H, 45H.
Products made from copper and copper alloys do not fall within the area of applicability of Regulation (EC) No. 1272/2008
of the European Parliament and Council on the Classification, Labeling and Packaging of Substances and Mixtures (CLP
Regulation) and are therefore not subject to the classification and labeling obligations.
To our knowledge, when used for their intended purpose and disposed of correctly (recycling), the contained substances
pose no threat to health or environment.
We would like to point out that the proportion of lead used here is not prohibited according to the REACH Regulation. It is
merely necessary to declare the use of this substance.

18/05/2022 TK/HW/SU Chr. Mayr GmbH + Co. KG

Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: +49 8341 804-0, Fax: +49 8341 804-421
Page 2 of 16 www.mayr.com, E-Mail: public.mayr@mayr.de
Installation and Operational Instructions for
ROBA-stop®-Z Type 892.101.0
Size 125 (E073 01 046 000 4 EN)

Safety Regulations
These Safety Regulations are user hints only and may not be complete!

General Guidelines Guidelines for Electromagnetic Compatibility

DANGER (EMC)
Danger of death! In accordance with the EMC directive 2014/30/EU, the individual
Do not touch voltage-carrying lines and components produce no emissions. However, functional
components. components e.g. mains-side energization of the brakes with
rectifiers, phase demodulators, ROBA®-switch devices or similar
controls can produce disturbance which lies above the allowed
Brakes may generate further risks, among other things: limit values. For this reason it is important to read the Installation
and Operational Instructions very carefully and to keep to the
EMC directives.

Application Conditions
The catalogue values are guideline values which
Hand injuries Danger of Contact with Magnetic
have been determined in test facilities. It may be
seizure hot surfaces fields
necessary to carry out your own tests for the
intended application. When dimensioning the
Severe injury to people and damage to objects may result if: brakes, please remember that installation situations, braking
 the electromagnetic brake is used incorrectly. torque fluctuations, permitted friction work, bedding-in condition
/ conditioning of the brake linings and wear as well as general
 the electromagnetic brake is modified.
ambient conditions can all affect the given values. These
 the relevant standards for safety and / or installation factors should therefore be carefully assessed, and alignments
conditions are ignored. made accordingly.
During the risk assessment required when designing the machine
or system, the dangers involved must be evaluated and removed  Mounting dimensions and connection dimensions must be
adjusted according to the size of the brake at the place of
by taking appropriate protective measures.
installation.
To prevent injury or damage, only specialist personnel are
allowed to work on the components.  Use of the brake in extreme environmental conditions or
They must be familiar with the dimensioning, transport, outdoors, directly exposed to the weather, is not permitted.
installation, inspection of the brake equipment, initial operation,  The brakes are designed for a relative duty cycle of 50 %. A
maintenance and disposal according to the relevant standards duty cycle > 50 % leads to higher temperatures, which cause
and regulations. premature aging of the noise damping and therefore lead to
an increase in switching noises. Furthermore, the switch
Before product installation and initial operation, function of the release monitoring can be impaired. The max.
please read the Installation and Operational permitted switching frequency is 180 1/h.
Instructions carefully and observe the Safety These values are valid for intermittent periodic duty S3 50 %.
Regulations. Incorrect operation can cause injury The permitted surface temperature on the brake flange must
or damage. At the time these Installation and Operational not exceed 80 °C at a max. ambient temperature of 40 °C.
Instructions go to print, the electromagnetic brakes accord with For higher requirements on the friction work in case of
the known technical specifications and are operationally safe at EMERGENCY STOP or at temperatures of up to 90 °C on the
the time of delivery. brake flange, special friction materials and noise damping are
 Technical data and specifications (Type tags and to be used.
documentation) must be followed.  The braking torque is dependent on the current bedding-in
 The correct connection voltage must be connected according condition of the brake. Bedding in / conditioning of the friction
to the Type tag and wiring guidelines. linings is necessary.

 Check electrical components for signs of damage before  The brakes are only designed for dry running. The torque is
putting them into operation. Never bring them into contact lost if the friction surfaces come into contact with oil, grease,
with water or other fluids. water or similar substances or any other foreign bodies.

 Please observe the EN 60204-1 requirements for electrical  The surfaces of the outer components have been phosphated
connection when using in machines. manufacturer-side to form a basic corrosion protection.

Only carry out installation, maintenance and CAUTION The rotors may rust up and seize up in
repairs in a de-energized, disengaged state corrosive ambient conditions and / or after
and secure the system against inadvertent longer downtimes.
switch-on. The user is responsible for taking appropriate
countermeasures.

18/05/2022 TK/HW/SU Chr. Mayr GmbH + Co. KG

Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: +49 8341 804-0, Fax: +49 8341 804-421
Page 3 of 16 www.mayr.com, E-Mail: public.mayr@mayr.de
Installation and Operational Instructions for
ROBA-stop®-Z Type 892.101.0
Size 125 (E073 01 046 000 4 EN)

Safety Regulations
These Safety Regulations are user hints only and may not be complete!

Dimensioning Intended Use

Attention! This safety brake is intended for use in electrically operated
When dimensioning the brake, please take into consideration elevators and goods elevators. Furthermore, this brake can be
that a load torque is present when selecting the protection. used as a braking device acting on the traction sheave or the
 Load torques reduce the deceleration torque available. shaft of the traction sheave, as part of the protection device
against overspeed for the car moving in upwards direction and
 Load torques may increase the output speed: as a braking element against unintended car movement.
 during a possible processing time in the controls
 during the brake downtime Grounding Connection
When calculating the friction work, please observe that the brake The brake is designed for Protection Class I. This protection
nominal torque is subject to a tolerance. covers not only the basic insulation, but also the connection of all
conductive parts to the protective conductor (PE) on the fixed
Climate Conditions installation. If the basic insulation fails, no contact voltage will
remain. Please carry out a standardized inspection of the
The electromagnetic brake is suitable for mounting / operation protective conductor connections to all contactable metal parts!
on electromotive elevator machinery in enclosed places of
installation with an ambient temperature of between -5 °C and
+40 °C. Class of Insulation F (+155 °C)
The insulation components on the magnetic coils are
CAUTION Reduction in braking torque possible manufactured at least to class of insulation F (+155 °C).
Condensation can form on the brake and cause
a loss in braking torque: Protection
 due to fast changes in temperature (mechanical) IP10: Protection against large body surfaces and
large foreign bodies > 50 mm in diameter. No protection against
 at temperatures of around or under
water.
freezing point
(electrical) IP54: Dust-proof and protected against contact as
The user is responsible for taking appropriate
well as against water spray from any direction.
countermeasures (e.g. forced convection,
heating, drain screw).
Brake Storage
CAUTION Brake malfunction possible
 Store the brakes in a horizontal position, in dry rooms and
Condensation can form on the brake and cause
dust and vibration-free.
malfunctions:
 Relative air humidity < 50 %.
 at temperatures around or under freezing
point, the brake can freeze over and not  Temperature without major fluctuations within a range from
release any more. -5 °C up to +40 °C.
The user is responsible for taking appropriate  Do not store in direct sunlight or UV light.
countermeasures (e.g. forced convection,  Do not store aggressive, corrosive substances (solvents /
heating, drain screw). acids / lyes / salts / oils / etc.) near to the brakes.
The system function must be checked by the user after longer For longer storage of more than 2 years, special measures are
downtimes. required (please contact the manufacturer).
Storage acc. DIN EN 60721-3-1 (including the limitations /
At high temperatures and in high humidity or
additions described above): classes 1K21; 1Z1; 1B1; 1C2; 1S11;
with occurring dampness, the rotors can seize
1M11
up to the friction surfaces after longer
downtimes.
Handling
Before installation, the brake must be inspected and found to
CAUTION Temperatures of over 80 °C on the brake be in proper condition.
mounting flange can have a negative effect on The brake function must be inspected both once attachment
the switching times, the braking torque levels has taken place as well as after longer system downtimes, in
and the noise damping behavior. order to prevent the drive starting up against possibly seized
linings.

18/05/2022 TK/HW/SU Chr. Mayr GmbH + Co. KG

Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: +49 8341 804-0, Fax: +49 8341 804-421
Page 4 of 16 www.mayr.com, E-Mail: public.mayr@mayr.de
Installation and Operational Instructions for
ROBA-stop®-Z Type 892.101.0
Size 125 (E073 01 046 000 4 EN)

Safety Regulations
These Safety Regulations are user hints only and may not be complete!

User-implemented Protective Measures: EN ISO 12100 Safety of machinery – General

principles for design - Risk assessment
 Please cover moving parts to protect against injury
and risk reduction
through seizure.
DIN EN 61000-6-4 Interference emission
 Place a cover on the magnetic part to protect against injury
through high temperatures. EN 12016 Interference immunity (for elevators,
escalators and moving walkways)
 Protection circuit: When using DC-side switching, the coil
must be protected by a suitable protection circuit according
to VDE 0580, which is integrated in mayr ®-rectifiers. To Liability
protect the switching contact from consumption when using The information, guidelines and technical data in these
DC-side switching, additional protective measures are documents were up to date at the time of printing. Demands on
necessary (e.g. series connection of switching contacts). previously delivered brakes are not valid.
The switching contacts used should have a minimum contact Liability for damage and operational malfunctions will not be
opening of 3 mm and should be suitable for inductive load taken if:
switching. Please make sure on selection that the rated
- the Installation and Operational Instructions are ignored or
voltage and the rated operating current are sufficient.
neglected.
Depending on the application, the switching contact can also
be protected by other protection circuits (e.g. mayr ®-spark - the brakes are used inappropriately.
quenching unit, half-wave and bridge rectifiers), although this - the brakes are modified.
may of course then alter the switching times. - the brakes are worked on unprofessionally.
 Take precautions against freeze-up of the friction - the brakes are handled or operated incorrectly.
surfaces in high humidity and at low temperatures.
Guarantee
Standards, Directives and Regulations  The guarantee conditions correspond with
Used and To Be Applied the Chr. Mayr GmbH + Co. KG sales and delivery
conditions.
DIN VDE 0580 Electromagnetic devices and
components, general specifications  Mistakes or deficiencies are to be reported to mayr ® at
once!
2014/35/EU Low Voltage Directive
2011/65/EU RoHS II - Directive CE Identification
2015/863/EU RoHS III- Directive in accordance with the Low Voltage Directive
CSA C22.2 No. 14-2010 Industrial Control Equipment 2014/35/EU (only in case of voltages > 75 V DC)
UL 508 (Edition 17) Industrial Control Equipment and / or the RoHS Directive 2011/65/EU with
2015/863/EU,
2014/33/EU Elevator Directive and the Elevator Directive 2014/33/EU
EN 81-20 Safety rules for the construction and (with the ID number of the respective inspection authority, for
installation of lifts – type examination tested brakes only)
Part 20: Passenger and goods
passenger lifts Conformity Markings
EN 81-50 Safety rules for the construction and in terms of the Canadian and American approval
installation of lifts - Examinations and
tests – Part 50: Design rules,
calculations, examinations and tests of
lift components

Marking
mayr ® components are clearly marked and described on the Type tag:

Product name Serial number Article number

Size/Type Voltage Power Braking torque DataMatrix code

18/05/2022 TK/HW/SU Chr. Mayr GmbH + Co. KG

Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: +49 8341 804-0, Fax: +49 8341 804-421
Page 5 of 16 www.mayr.com, E-Mail: public.mayr@mayr.de
Installation and Operational Instructions for
ROBA-stop®-Z Type 892.101.0
Size 125 (E073 01 046 000 4 EN)

18.3 11 23 18.5 18.4 21/22 20 18.1 18.3

18.2 18.7 18.9/18.10 18.6 9 19 18.6 18.7 18.8/18.11 18.2

Fig. 1 Fig. 2 Fig. 3

11.4 11.3
Installation dimension
115 +1 mm 14 11.2
24 4
20 11.1
7 3
21/22 2
2.1 5 11.5
1.1

1.1 Fig. 5
12
1
Insertion position for Insertion position for
13 brake circuit 2 inspection brake circuit 1 inspection
1.2 Item 10

15
5

2 6

8 b b 14

Air gap “a”

Fig. 4

Fig. 6 Fig. 7

18/05/2022 TK/HW/SU Chr. Mayr GmbH + Co. KG

Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: +49 8341 804-0, Fax: +49 8341 804-421
Page 6 of 16 www.mayr.com, E-Mail: public.mayr@mayr.de
Installation and Operational Instructions for
ROBA-stop®-Z Type 892.101.0
Size 125 (E073 01 046 000 4 EN)

Parts List (Only use mayr  original parts)

Item Name Pcs.
1 Hub 1
1.1 O-ring D60 x 3 2
1.2 Set screw M6 x 10 1
2 Brake body 1
2.1 Magnetic coil 1
3 Cap screw M8 x 85 3
4 Washer D16 / 8.4 x 1.6 3
5 Rotor 1 1
6 Rotor 2 1
7 Distance bolt 3
8 Thrust spring D15.5 / 2.8 x 39.5 4
9 Cable 2 x AWG18 1
10 Reference gauge 2
11 Release monitoring (page 12) 1
11.1 Microswitch 1
11.2 Hexagon head screw M5 x 20 1
11.3 Hexagon nut M5 1
11.4 Spring washer A5 1
11.5 Cap screw M4 x 8 2
12 1)
Hub 1
13 Elastomeric element 1
14 Armature disk 1
15 Brake plate 1
16 2)
Headless screw M8 x 30 2
17 2) Plastic tube D10 / 8 x 14 2
18 3) Hand release 1
18.1 Switch bracket A 1
18.2 Switch bracket B 2
18.3 Cap screw M8 x 14 4
18.4 Hand release rod 1
18.5 Hexagon nut M16 1
18.6 Headless screw M8 x 30 2
18.7 Flat headed screw M8 x 10 2
18.8 Thrust spring holder 1
18.9 Cap screw M6 x 25 1
18.10 Washer A6.4 1
18.11 Thrust spring D15.5 / 2.5 x 28 1
19 Noise damping 4
20 Grounding strand 1
21 Cap screw M4 x 8 2
22 Contact washer M4 2
23 4) Hexagon nut M8 1
24 Type tag 1
We reserve the right to make dimensional and constructional alterations!
1)
On article number 8253118, the hub is not included in the standard scope of delivery.
2)
Items 16 and 17 are included loose in delivery and are not shown in the Figure.
3)
On article number 8292346, the hand release is not included in the standard scope of delivery.
4)
Plastic nut, serves only as transportation lock.

18/05/2022 TK/HW/SU Chr. Mayr GmbH + Co. KG

Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: +49 8341 804-0, Fax: +49 8341 804-421
Page 7 of 16 www.mayr.com, E-Mail: public.mayr@mayr.de
Installation and Operational Instructions for
ROBA-stop®-Z Type 892.101.0
Size 125 (E073 01 046 000 4 EN)

Table 1: Technical Data

Article number 8227821 8253118 8292346
Nominal voltage 90 V 90 V 55 V
Overexcitation voltage 180 V 180 V 110 V
Coil power (nominal power at 20°C) 76 W 76 W 71 W
Coil power on overexcitation 303 W 303 W 284 W
Overexcitation time span 1s
Nominal braking torque (+60 %) 100 (2 x 50) Nm
Rotor thickness, new condition 10.5 mm
Nominal air gap “a” total (braked) 0.5 +0.25 mm
Limit air gap “a” for rotor replacement 1.0 mm
Inspection air gap “b” released, per single circuit min. 0.15 mm
Tightening torque Item 1.2 3 Nm
Tightening torque Item 3 24 Nm
Tightening torque Item 16 8.5 Nm
Tightening torque Item 18.3 24 Nm
Tightening torque Item 18.6 8.5 Nm
Tightening torque Item 18.7 8.5 Nm
Tightening torque Item 18.9 10 Nm
Max. Speed 2250 rpm
Max. permitted friction work for both rotors at a speed of 1800 rpm 5000 J
Weight 11.4 kg

Table 2: Switching Times

Attraction t2 50 ms
Drop-out t0 (DC): 25 ms
Drop-out t 50 (DC) 5): 35 ms
Drop-out t 90 (DC) 5): 40 ms
Drop-out t11 AC 180 ms
Drop-out t1 AC 6) 340 ms

5)
Referring to the nominal braking torque
6)
Referring to the effective braking torque
The stated switching times can only be achieved using the respective correct electrical wiring. This also refers to the
protection circuit for brake control and the response delay times of all control components. If the brake is operated using
overexcitation, the respective switch-on and switch-off times for overexcitation must be taken into account.
The use of varistors for spark quenching increases the DC-side switching times.

18/05/2022 TK/HW/SU Chr. Mayr GmbH + Co. KG

Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: +49 8341 804-0, Fax: +49 8341 804-421
Page 8 of 16 www.mayr.com, E-Mail: public.mayr@mayr.de
Installation and Operational Instructions for
ROBA-stop®-Z Type 892.101.0
Size 125 (E073 01 046 000 4 EN)

Application Installation Conditions

 ROBA-stop®-Z brake for use as a holding brake with  The eccentricity of the shaft end in relation to the mounting
occasional EMERGENCY STOP braking actions (max. 10 pitch circle must not exceed 0.2 mm.
per day).  The positional tolerance of the threads for the cap screws (3)
 The max. permitted speed and friction work (see Technical must not exceed 0.2 mm.
Data) must be observed.  The axial run-out deviation of the screw-on surface to the
shaft must not exceed the permitted axial run-out tolerance of
0.05 mm acc. DIN 42955 R.
Design The reference diameter is the pitch circle diameter for
securement of the brakes.
The ROBA-stop®-Z brake is a spring applied, electromagnetically Larger deviations can lead to a drop in torque, to continuous
releasing dual circuit safety brake, which applies a defined grinding on the rotors and to overheating.
braking effect after the voltage is switched off or after a voltage
failure.  The fit tolerance of the shaft must be selected so that the hub
This brake is combined with a positive-locking, flexible coupling toothing (1) is not widened. Widening of the toothing leads to
(ROBA®-ES coupling) for connecting two shafts whilst the rotors (5 and 6) jamming on the hub (1) and therefore to
compensating for shaft misalignments. brake malfunctions.
The ROBA®-ES coupling compensates for axial, radial and Recommended fit tolerance for the shaft: k6
angular shaft misalignments. The max. permitted joining temperature of 150 °C must not be
exceeded.
 The O-rings (1.1) on the hub (1) must be lightly greased.
Function  The rotors (5 and 6) and the brake surfaces must be oil and
The ROBA-stop®-Z brake is a spring applied, electromagnetic grease-free.
safety brake.  A suitable counter friction surface (steel or cast iron) must be
used. Sharp-edged interruptions on the friction surfaces must
Spring applied function (brake): be avoided. Recommended surface quality in the area of the
In de-energized condition, thrust springs (8) press against the friction surface Ra = 0.8 – 1.6 µm. The mounting surface must
armature disk (14). Rotor 2 (Item 6) is held between the armature be turned. The surface must be bare or FE-phosphated (layer
disk (14) and the brake plate (15), rotor 1 (Item 5) is held between thickness approx. 0.5 µm) without oil.
the brake body (2) and the machine wall via frictional locking. If corrosion protection is applied, the device must be
The braking torque is introduced into the drive line via the inspected for possible effects on the braking torque.
toothing of the rotors (5 and 6) and the hub (1). In particular customer-side mounting surfaces made of
grey cast iron are to be rubbed down additionally with
Electromagnetic function (release): sandpaper (grain  60 to 100).
Due to the magnetic force of the coil in the brake body (2), the
 The toothings of the hub (1) and the rotors (5 and 6) must not
armature disk (14) is attracted against the spring pressure (8) to
be oiled or greased.
the brake body (2). The brake is released and the brake rotors (5
and 6) with the hub (1) can rotate freely.  Friction value-increasing surface treatments are not
permitted.
Safety brakes:  Please abstain from using cleaning agents containing
The ROBA-stop®-Z brake brakes reliably solvents, as they could affect the friction material.
and safely in the event of a power switch-off, a power failure or an
EMERGENCY STOP.

Scope of Delivery / State of Delivery

The ROBA-stop®-Z brake is pre-assembled.
On brake article number 8253118, the hub (12) is not included in
the standard scope of delivery.
Brake article number 8292346 is designed without hand release
(18).
The release monitoring (11) device is installed and set
manufacturer-side.
The brakes are set manufacturer-side to the braking torque
stipulated on order.
Please check the scope of delivery according to the Parts List as
well as the state of delivery immediately after receiving the goods.
mayr ® will take no responsibility for belated complaints.
Please report transport damage immediately to the deliverer.
Please report incomplete delivery and obvious defects
immediately to the manufacturer.

18/05/2022 TK/HW/SU Chr. Mayr GmbH + Co. KG

Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: +49 8341 804-0, Fax: +49 8341 804-421
Page 9 of 16 www.mayr.com, E-Mail: public.mayr@mayr.de
Installation and Operational Instructions for
ROBA-stop®-Z Type 892.101.0
Size 125 (E073 01 046 000 4 EN)

Installation
All the screws (except the cap screw Item 21) 20. Mount plastic hoses (17) onto both headless screws (16) in
and the set screws mounted by the customer order to dampen vibration noises.
must be tightened using the tightening torque 21. Insert the elastomeric element (13) in the claws of the hub
stated in Table 1. (1).
We recommend that you secure the screws 22. Mount the hub (12) onto the motor shaft with the inserted
using Loctite 243. key and bring it into the correct axial position (installation
1. Remove all 3 hexagon nuts (Item 23 / transportation lock) dimension 115 +1 mm, see Fig. 4).
and remove the brake plate (15) from the brake body (2). 23. Establish the positive locking between the hub (12) and the
2. Mount the hub (1) onto the shaft with inserted key and elastomeric element (13).
secure it axially. Due to the pre-tension on the flexible elastomeric element
Axial securement takes place using the set screw (1.2), (13), an axial installation force is required when joining both
which presses onto the customer-side key. hubs (1 and 12) (Fig. 5). The force required can be reduced
by lightly greasing the elastomeric element (13).
3. Lightly grease the first O-ring (1.1) and insert it into the hub
(1) groove nearest to the machine wall.
4. Push the rotor 1 (Item 5) over the inserted O-ring (1.1) onto Use PU-compatible lubricants
the hub (1) by hand using light pressure (the rotor collar (e. g. Vaseline or HP 222)!
should be facing away from the machine wall).
Make sure that the toothing moves easily.
5. Lightly grease the second O-ring (1.1) and insert it into the After joining both hubs, no axial pressure must
other (not occupied) hub (1) groove. be placed on the elastomeric element (13).
6. Push brake body (2) over the hub (1) and insert it in the Keep to the installation dimension 115 +1 mm,
gear housing. see Fig. 4.
7. Push the rotor 2 (6) over the O-ring (1.1) onto the hub (1)
by hand using light pressure (the rotor collar should be 24. Check air gap “a” (Fig. 4).
facing the machine wall). The nominal air gap acc. Table 1 must be given.
Make sure that the toothing moves easily. 25. Check the air gap single circuits "b" (Fig. 4) on rotors 1
8. Insert the cap screws (3) including the washers (4) in the and 2.
distance bolts (7) through the brake plate (15). The respective minimal air gap acc. Table 1 must be given.
9. Secure the brake evenly all around using the cap screws
(3) with a torque wrench.
10. Attach the grounding strand (20) onto the brake body (2)
Adjustment
using the cap screw (21) and the contact washer (22). The brakes are equipped manufacturer-side with
To do this, the contact washer (22) must be inserted the respective springs for the braking torque
between cable lug and brake body (2). stated on the Type tag (24). Adjustment is not
11. Attach the grounding strand (20) onto the brake plate (15) necessary. Adaptions or modifications are not
using the cap screw (21) and the contact washer (22). To permitted as a rule. This rule also applies to the manufacturer-
do this, the contact washer (22) must be inserted between side adjusted noise damping. The switches are also adjusted
cable lug and brake plate (15). manufacturer-side. Despite great care during the manufacturer-
Steps 12 to 20 do not apply for article number 8292346. side adjustment, re-adjustment might be necessary after
installation due to transportation and handling. Furthermore,
12. Screw the headless screws (18.6) on both sides into the such switches cannot be considered fail-safe.
armature disk (14). Please also observe the section ‘Release Monitoring’.
13. Attach both switch brackets B (18.2) in the correct position
onto the brake body (2) using the flat headed screws (18.7).
14. Secure the thrust spring holder (18.8) onto the brake body Noise Damping (Item 19 / Fig. 2)
(2) using the cap screw (18.9) and the washer (18.10), so
that the pin of the thrust spring holder (18.8) points in the The noise damping was set and adjusted
direction of the knob of switch bracket B (18.2). manufacturer-side. However, this component is
subject to aging dependent on the application
15. Tilt switch bracket B (18.2) and join the thrust spring (18.11)
or operating conditions (torque adjustment,
between the thrust spring holder (18.8) and switch bracket
switching frequency, ambient conditions,
B (18.2).
system vibrations etc.).
16. Screw switch bracket A (18.1) onto switch bracket B (18.2) Replacing the damping element is only
on both sides using the cap screws (18.3). permitted at the mayr ® site of manufacture.
17. Screw the hexagon nut (18.5) up to contact on the thread
end onto the hand release rod (18.4).
18. Screw the hand release rod (18.4) into switch bracket A
(18.1) and counter the hexagon nut (18.5) with an open-end
wrench.
19. Screw both headless screws (Item 16 / not shown) as
contact for the hand release into the gear housing.

18/05/2022 TK/HW/SU Chr. Mayr GmbH + Co. KG

Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: +49 8341 804-0, Fax: +49 8341 804-421
Page 10 of 16 www.mayr.com, E-Mail: public.mayr@mayr.de
Installation and Operational Instructions for
ROBA-stop®-Z Type 892.101.0
Size 125 (E073 01 046 000 4 EN)

Electrical Connection and Wiring Magnetic Field Removal

In safety applications, the rules for risk minimisation and error AC-side switching
avoidance (e.g. redundance, diversity, resistance, monitoring etc.) The power circuit is interrupted
must be observed during electrical activation. in front of the rectifier. The
The power is connected using a 2-core cable (9). magnetic field slowly reduces.
This delays the rise in braking
The brake must only be operated with torque.
overexcitation (see Technical Data).
When switching times are not
important, please switch AC-
DC current is necessary for operation of the brake. The coil side, as no protective
nominal voltage is indicated on the Type tag as well as on the measures are necessary for
brake body and is designed according to the DIN IEC 60038 coil and switching contacts.
(± 10 % tolerance). The brake must only be operated with Coil
overexcitation (e.g. using a ROBA®-switch or -multiswitch fast
acting rectifier or phase demodulator). The connection
possibilities can vary dependent on the brake equipment. Please
follow the exact connections according to the Wiring Diagram.
The manufacturer and the user must observe the applicable F1: external fuse
regulations and standards (e.g. DIN EN 60204-1 and DIN VDE
0580). Their observance must be guaranteed and double- AC-side switching means low-noise switching; however, the
checked! brake engagement time is longer (approx. 6-10 times longer than
with DC-side disconnection), use for non-critical braking times.
Grounding Connection
DC-side switching
The brake is designed for Protection Class I. This protection
covers therefore not only the basic insulation, but also the The power circuit is interrupted
connection of all conductive parts to the protective conductor (PE) between the rectifier and the
on the fixed installation. If the basic insulation fails, no contact coil as well as mains-side. The
voltage will remain. Please carry out a standardized inspection of magnetic field reduces
the protective conductor connections to all contactable metal extremely quickly. This causes
parts! a quick rise in braking torque.

Device Fuses When switching DC-side, high

voltage peaks are produced in
To protect against damage from short circuits, please add the coil, which can lead to wear
suitable device fuses to the mains cable. on the switching contacts from
Coil sparks and to destruction of the
Switching Behavior insulation.
The reliable operational behavior of a brake is to a large extent
dependent on the switching mode used. Furthermore, the
switching times are influenced by the temperature and the air gap
between the armature disk and the coil carrier (dependent on the F1: external fuse
wear condition of the linings).
DC-side switching means short brake engagement times (e.g.
Magnetic Field Build-up for EMERGENCY STOP operation); however, louder switching
noises.
When the voltage is switched on, a magnetic field is built up in the
brake coil, which attracts the armature disk to the coil carrier and
releases the brake.
Protection Circuit
When using DC-side switching, the coil must be protected by a
suitable protection circuit according to VDE 0580, which is
integrated in mayr ®-rectifiers. To protect the switching contact
from consumption when using DC-side switching, additional
protective measures are necessary (e.g. series connection of
switching contacts). The switching contacts used should have a
minimum contact opening of 3 mm and should be suitable for
inductive load switching. Please make sure on selection that the
rated voltage and the rated operating current are sufficient.
Depending on the application, the switching contact can also be
protected by other protection circuits (e.g. mayr ®-spark quenching
unit, half-wave and bridge rectifiers), although this may of course
then alter the switching times.

18/05/2022 TK/HW/SU Chr. Mayr GmbH + Co. KG

Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: +49 8341 804-0, Fax: +49 8341 804-421
Page 11 of 16 www.mayr.com, E-Mail: public.mayr@mayr.de
Installation and Operational Instructions for
ROBA-stop®-Z Type 892.101.0
Size 125 (E073 01 046 000 4 EN)

Permitted Shaft Misalignments Shaft Alignment

ROBA®-ES coupling compensates for radial, axial and angular Exact alignment of the shafts improves the running smoothness
shaft misalignments (Fig. 3) without losing its backlash-free of the coupling substantially, reduces the load on the shaft
function. However, the permitted shaft misalignments indicated in bearings and increases the coupling service lifetime.
Table 3 must not simultaneously reach their maximum value. We recommend alignment of the coupling using a dial gauge or
If more than one kind of misalignment takes place simultaneously, special laser on drives operating at very high speeds.
they influence each other. This means that the permitted
misalignment values are dependent on one another, see Fig. 4.
The sum total of the actual misalignments in percent of the
maximum value must not exceed 100 %.

Δ Kr [%] Radial misalignment

The permitted misalignment values given in Table 3 refer to
coupling operation at nominal torque, an ambient temperature of
+30 °C.
If the coupling is operated in other or more extreme operating
Δ Kw [%]
conditions, please contact the manufacturers. Angular misalignment

Table 3
Max. Permitted Shaft Misalignments
ΔKa ± 1.5 mm

ΔKr 0.11 mm

ΔKw 0.9 °

Δ Ka [%] Axial displacement

Fig. 9

Axial Radial Angular

displacement misalignment misalignment

Fig. 8

18/05/2022 TK/HW/SU Chr. Mayr GmbH + Co. KG

Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: +49 8341 804-0, Fax: +49 8341 804-421
Page 12 of 16 www.mayr.com, E-Mail: public.mayr@mayr.de
Installation and Operational Instructions for
ROBA-stop®-Z Type 892.101.0
Size 125 (E073 01 046 000 4 EN)

Braking Torque Dual Circuit Brake Functional Inspection

The (nominal) braking torque is the torque effective in the shaft The ROBA-stop®–Z brake is equipped with a double safety
train on slipping brakes, with a sliding speed of 1 m/s referring to (redundant) braking system. If one brake circuit fails, min. 50 % of
the mean friction radius. the braking torque remain. The single brake circuit inspection is
The brake is loaded statically when used as a service brake and carried out using the reference gauges (10) included in delivery.
loaded dynamically in EMERGENCY STOP operation.
Respectively, there are different speed values for the friction DANGER Should the load begin to move after tilting the
material, which in practice also leads to different friction values feeler gauges (10) or should it fail to react to
and therefore braking torques. Amongst other things, the braking the braking procedure, the reference gauges
torque is dependent on the respective quality / condition of the must be pivoted back and removed
friction surfaces (conditioning). Therefore, bedding in of the brake immediately.
linings on newly installed brakes or on rotor replacement when The dual circuit braking function is not
mounted is required, taking into account the permitted loads: The guaranteed.
following applies as a reference value for the bedding in of new Shut down the system, lower and secure the
brake linings. The load in new condition may not be more than 50 load, remove and inspect the brake.
% of the max. friction work, acc. Technical Data. This process is Please observe the accident prevention
to be carried out at reduced speed, approx. 30 % of the operating regulations.
speed.
If the bedding in should take place under works-specific Remove the reference gauges (ideally attached to the motor or
conditions, we ask you to contact us, so that we can provide the the gearbox).
appropriate parameters.
Friction materials develop their optimum effect only under speed Inspection brake circuit 1 (mounting-side, see Fig. 1):
at the appropriate contact pressure, as continuous regeneration 1. Push both reference gauges, 180° offset to each other, with
of the friction surface then takes place (torque consistency). the flattened section between the brake body (2) and the
Permanent grinding of the rotors can lead to overheating / machine wall.
damage to the brake linings, and therefore to a drop in braking Set up the reference gauges at 90° (tilt) and hold in this
torque. position (no spring force on rotor 1 (Item 5)).
Furthermore, friction materials are subject to aging, which is also
influenced, among other things, by higher temperatures and other 2. Energize the brake and put the drive into operation.
ambient influences. We recommend regular inspection of the 3. De-energize the brake (= EMERGENCY STOP) and inspect
braking torque (1 x per year) including the respective dynamic the stopping distance.
braking actions as a refresher. 4. Turn the flat sections of the reference gauges once more
and remove them from the brake.

Brake Inspection (before brake initial operation) Inspection brake circuit 2 (brake plate-side, see Fig. 1):
 Air gaps inspection (Fig. 4) 1. Push both reference gauges, 180° offset to each other, with
Measure the air gap “a” (brake de-energized) several times the flattened section between the armature disk (14) and the
on the circumference. brake plate (15). Set up the reference gauges at 90°
The nominal air gap acc. Table 1 must be given. (tilt) and hold in this position (no spring force on rotor 2 (Item
Measure the min. individual air gap "b" (brake energized) of 6)).
brake circuit 1 (inside) and brake circuit 2 (outside) several
times on the circumference. 2. Energize the brake and put the drive into operation.
The respective minimal air gap acc. Table 1 must be given. 3. De-energize the brake (= EMERGENCY STOP) and inspect
 Braking torque inspection: the stopping distance.
Please compare the requested braking torque with the 4. Turn the flat sections of the reference gauges once more
torque stated and remove them from the brake.
on the Type tag (24).
 Release function inspection Attach the reference gauges to the motor or gearbox again.
by energizing the brake.
 Switch function inspection of the release monitoring
with microswitch (NO contact)
Brake de-energized  Signal “OFF”
Brake energized  Signal “ON”
 Hand release functional inspection
By deflecting the hand release (18) manually, the friction
linings are relieved. The brake is free but for a residual
torque of max. 8 %.

When actuating the hand release (18), a

switching signal of the release monitoring
device (11) cannot be guaranteed.

18/05/2022 TK/HW/SU Chr. Mayr GmbH + Co. KG

Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: +49 8341 804-0, Fax: +49 8341 804-421
Page 13 of 16 www.mayr.com, E-Mail: public.mayr@mayr.de
Installation and Operational Instructions for
ROBA-stop®-Z Type 892.101.0
Size 125 (E073 01 046 000 4 EN)

Release Monitoring
The brakes are supplied with manufacturer-side installed and Customer-side Inspection after Attachment
adjusted release monitoring device.
For customer-side connection as NO contact.
The microswitch (11.1) emits a signal for every brake condition
change: "brake opened or brake closed" Brake de-energized  Signal "OFF",
The customer is responsible for a signal evaluation of both Brake energized  Signal “ON”
conditions. For customer-side connection as NC contact.
From the point at which the brake is energized, a time span of Brake de-energized  Signal “ON”,
three times the separation time must pass before the switch
signal on the release monitoring is evaluated. Brake energized  Signal “OFF”

11.4 11.3
Microswitches cannot be guaranteed fail-safe.
Therefore, please ensure appropriate access
14 11.2 for replacement or adjustment.
The switching contacts are designed so that
20 11.1 they can be used for both small switching
powers and medium ones. However, after
21/22 2 switching a medium switching power, small
switching powers are no longer reliably
possible.
5 11.5 In order to switch inductive, capacitive and non-
linear loads, please use the appropriate
Fig. 10 protection circuit to protect against electric arcs
and unpermitted loads!
Function
When the magnetic coil (2.1) is energized in the brake body (2),
the armature disk (14) is attracted to the brake body (2), the
microswitch (11.1) emits a signal, the brake is released.

When actuating the hand release (18), a

switching signal of the release monitoring
device (11) cannot be guaranteed.

Microswitch Wiring Diagram:

NC contact
Grey connection
Connection when
2 brake closed

COM contact 1
Black connection 4
NO contact
Blue connection
Connection when
brake released

Microswitch Specification
Characteristic values for 250 V~ / 3 A
measurement:
Minimum switching power: 12 V, 10 mA DC-12
Recommended switching 24 V, 10...50 mA
power: DC-12
for maximum lifetime DC-13 with freewheeling
and reliability diode!
Usage category acc. IEC 60947-5-1:
DC-12 (resistance load), DC-13 (inductive load)

18/05/2022 TK/HW/SU Chr. Mayr GmbH + Co. KG

Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: +49 8341 804-0, Fax: +49 8341 804-421
Page 14 of 16 www.mayr.com, E-Mail: public.mayr@mayr.de
Installation and Operational Instructions for
ROBA-stop®-Z Type 892.101.0
Size 125 (E073 01 046 000 4 EN)

Maintenance Replacing the Rotors (5 and 6)

ROBA-stop®–Z brakes are mainly maintenance-free. The friction Before Replacing the Rotors
lining pairing is robust and wear-resistant. This ensures a  Cleaning of the brake.
particularly long service lifetime of the brake.
However, the friction lining is subject to operational wear on
frequent EMERGENCY STOP braking actions. Normally, such Please observe the section “Cleaning the
occurrences are recorded and saved by the elevator control, Brake”, see below.
or they require the intervention of qualified personnel. When
carrying out this maintenance work (especially when taking DIN
EN 13015 Appendix A into account), the causes of the  Measure the rotor thickness “new condition” (nominal
malfunction must be determined, assessed and removed by dimension 8 -0.05 mm).
specialist personnel. Causal events such as the air gap can be Rotor (5 and 6) replacement is carried out by following the
checked and respective measures can be taken. Installation section (page 9) backwards.
The brakes on the elevator system must be maintained and
repaired by a specialist employee, taking into consideration the DANGER
type and intensity of use of the system. The drive brake must be load-free on hoist
The following inspections / tests are to be conducted within the drives. Otherwise there is a danger of load
scope of the defined elevator maintenance interval during crashes!
maintenance and repairs.
1. Visual inspection
 Inspection of condition in accordance with the regulations
 Brake rotors: in particular the exterior appearance of the Information on the Components
brake surfaces The friction material contains different inorganic and organic
- wear compounds, which are integrated into a system of hardened
- free of oil / lubricants binding agents and fibers.
- sticking of linings
Possible hazards:
2. Tightening torque inspection of the fixing screws on the No potential dangers have been recognized so far when the
brakes. If the brake fixing screws are covered with sealing brake is used according to its intended purpose. When grinding in
lacquer, a visual inspection for damage of the sealing is the brake linings (new condition) and also in case of
sufficient. EMERGENCY STOP braking actions, functional wear can occur
3. Inspection of the air gap – braked (wear on the friction linings); on open brake designs, fine dust can
4. Inspection of toothing backlash from the splined motor shaft be emitted.
to the rotors (5 and 6)
Max. permitted toothing backlash 0.3° Classification: Hazardous property
Attention: H-classification: H372
5. Running noise (brake rotors) during operation
Attention: Permanent grinding of the rotors can lead to
overheating / damage to the brake linings, and therefore to a Protective measures and rules of behavior:
drop in braking torque. If such indications are present, it is Do not inhale dusts.
essential that the braking torque is checked and the rotors Vacuum the dusts at the point of origin (tested suction devices,
replaced if required independent of the inspection or the tested filters acc. DIN EN 60335-2-69 for dust classes H;
determined wear value! maintenance of the suction devices and filter replacement at
regular intervals).
6. Braking torque or delay inspection (individual brake circuits)
If local dust suction is not possible or is insufficient, the entire
at least once per year (within the scope of the maintenance /
work area must be ventilated using appropriate technology.
main inspection)
Additional information:
In order to inspect the wear condition of the This friction lining (asbestos free) is not a dangerous product in
rotors (5 and 6), please measure the air gap terms of the EU Directive.
"a", see Fig. 4.
If the brake limit air gap (1.0 mm) has been
reached, meaning that the friction linings are Cleaning the Brake
worn down, the braking torque is lost and the
rotors (5 and 6) must be replaced.
Brake de-installation is carried out by following Do not clean the brake using compressed air,
the instructions in the section Installation (page brushes or similar devices!
9) backwards.
 Wear safety gloves / safety goggles.
7. Hand release function inspection.  Use a suction system or wet towels to clean off the brake
dust.
Automatic resetting of the hand release to its  Do not inhale brake dust.
initial position (after actuation) must be given.  In case of dust formation, a dust mask FFP 2 is
recommended.

18/05/2022 TK/HW/SU Chr. Mayr GmbH + Co. KG

Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: +49 8341 804-0, Fax: +49 8341 804-421
Page 15 of 16 www.mayr.com, E-Mail: public.mayr@mayr.de
Installation and Operational Instructions for
ROBA-stop®-Z Type 892.101.0
Size 125 (E073 01 046 000 4 EN)

Disposal
Our electromagnetic brake components must be disposed of Guidelines on the WEEE Directive 2012/19/EU
separately as they consist of different materials. Please also Avoidance of waste from electrical and electronic devices and the
observe the relevant authority regulations. Code numbers may reduction of such waste through recycling.
vary according to the disassembling process (metal, plastic and Our electromagnetic products (brakes, clutches) as well as the
cables). components required to control them (rectifiers) are frequently
used in electrical and electronic devices within the appropriate
Electronic Components (Rectifier / Switch): area of application of WEEE, independent of the applicable
Products which have not been disassembled can be disposed of product categories.
under Code No. 160214 (mixed materials) or components under The stated products do not fall within the area of application of
Code No. 160216, or can be disposed of by a certified disposal this Directive. They have been classified as electromagnetic /
firm. electronic components (VDE 0580) or as electronic equipment
Brake bodies made of steel with coil/cable and all other steel (DIN EN 50178), and have been determined for installation in
components: devices for "use in accordance with the intended purpose". Only
Steel scrap (Code No. 160117) products which are to be viewed as devices in terms of the
Directive and not as parts or components are subject to
All aluminum components: registration obligations.
Non-ferrous metals (Code No. 160118)
Brake rotor (steel or aluminum pads with friction linings):
Brake linings (Code No. 160112)
Seals, O-rings, V-seals, elastomers, terminal boxes (PVC):
Plastic (Code No. 160119)

Malfunctions / Breakdowns:

Malfunction Possible Causes Solutions

 Incorrect voltage on rectifier  Apply correct voltage
 Rectifier failure  Replace rectifier
Brake does not release
 Air gap too large (worn rotors)  Replace rotors
 Coil interrupted  Replace brake

Brake engagement delayed

 Brake is switched AC-side  Switch DC-side
on EMERGENCY STOP

Release monitoring does not  Brake does not release  Solution as above
switch  Defective microswitch  Replace the microswitch (manufacturer-side)

18/05/2022 TK/HW/SU Chr. Mayr GmbH + Co. KG

Eichenstraße 1, D-87665 Mauerstetten, Germany
Phone: +49 8341 804-0, Fax: +49 8341 804-421
Page 16 of 16 www.mayr.com, E-Mail: public.mayr@mayr.de
 U.I.LAPP GmbH
Schulze-Delitzsch-Straße 25 GEBRAUCHSANWEISUNG SKINTOP® MS-M, MSR-M, MS-M-XL, MSR-M-XL
D-70565 Stuttgart
Tel.0711/7838-1010
INSTRUCTION SHEET MS-SC-M, MS-SC-M-XL
Fax.0711/7838-2640
Internet:www.lappkabel.de

Klemm- und Dichtbereich

Clamping and Sealing range Approbationen
Bezeichnung
Approvals
Product
EN 50262 UL 514 B

Größe/Size Kat.der Anzugsdreh- Klemm- Diameter ∅

M Zug- momente bereich inch mm
entlastung Nm Ø mm
MS-M, MS-M-XL 3,5 - 7 .12 - .27 3,5 - 7
12x1,5 MSR-M, MSR-M-XL A 8 3,5 - 5 .04 - .20 1-5
MS-SC-M, MS-SC-M-XL 3,5 – 7 .12 - .27 3,5 - 7
MS-M, MS-M-XL 4,5 - 10 .17 - .35 4,5 - 10
16x1,5 MSR-M, MSR-M-XL A 10 3,5 - 7 .08 - .27 2-7
MS-SC-M, MS-SC-M-XL 4,5 – 9 .17 - .35 4,5 – 9
This drawing has to be changed by CAD only

MS-M, MS-M-XL 7 – 13 .27 - .51 7 – 13

Copyrights according to DIN ISO 16016

20x1,5 MSR-M, MSR-M-XL A 12 5 - 10 .20 - .04 5 - 10

MS-SC-M, MS-SC-M-XL 7 – 12,5 .27 - .49 7 – 12,5
MS-M, MS-M-XL 9 – 17 .35 - .65 9 – 17
25x1,5 MSR-M, MSR-M-XL A 12 6 - 13 .23 - .51 6 - 13
MS-SC-M, MS-SC-M-XL 9 – 16,5 .35 - .65 9 – 16,5
MS-M, MS-M-XL 11 - 21 .43 - .83 11 - 21
32x1,5 MSR-M, MSR-M-XL A 18 7 - 15 .27 - .59 7 - 15
MS-SC-M, MS-SC-M-XL 11 - 21 .43 - .83 11 - 21
MS-M, MS-M-XL 19 - 28 .75 – 1.1 19 - 28
40x1,5 MSR-M, MSR-M-XL A 18 15 - 23 .59 - .9 15 - 23
MS-SC-M, MS-SC-M-XL 19 - 28 .75 – 1.1 19 - 28
MS-M, MS-M-XL 27 - 35 1.06 – 1.38 27 - 35
50x1,5 MSR-M, MSR-M-XL A 20 22 - 29 .87 – 1.14 22 - 29
MS-SC-M, MS-SC-M-XL 27 - 35 1.06 – 1.38 27 - 35
MS-M 34 - 45 1.34 – 1.77 34 - 45
63x1,5 A 20
MSR-M 28 - 39 1.1 – 1.53 28 - 39

Bemerkungen/ Remarks Schutzart: IP 68; 5bar/30min.nach EN 60 529

Diese Zeichnung darf nur mittels CAD geändert werden.

IP 69K nach DIN 40 050

1. SKINTOP ins Gehäuse schrauben oder mit Gegenmutter festziehen
Screw SKINTOP into housing or tighten with locknut
2. Leitung durchziehen
Urheberschutz nach DIN ISO 16016

Put cable through

3. Hutmutter mit empfohlenem Drehmoment festziehen
Tighten nut with recomanded tightening torque
SKINTOP®

Ohne Gegenmutter: Usage without Locknut:

NUR IN GEWINDEBOHRUNGEN ONLY IN THREADED
VERWENDEN! HUB!

1 inch = 25,4mm
Temperaturbereich: –25 bis +100°C
Temperature range: -25 up to +100°C

UL File No. E 79903, Control Number 54 B 2

Hinweis / Note:
Sollte der Inhalt dieser Verpackung auf neue Verpackungen verteilt werden, so muss jeder neuen Verpackung eine Kopie dieser Betriebsanleitung beigelegt werden.
If the content of this bag will be split on two or more units, a copy of this instruction sheet must be placed in every packing units.
Art.Nr. 91100008 BS 04/2889-5

Druckfarbe: schwarz, Papierfarbe: hellgelb "CARNEVAL" 80g/qm (igepa Art.Nr.323-31)

Größe angepasst auf DIN A5, Falzung Kreuzbruch, Druck aussen
Toleranzen / tolerances: Werkstoff / material: Oberfläche / surface Gewicht / weight: Volumen / volume: Farbe / color:
DIN Papier
Bearb. Datum/date Name/name Geprüft Datum / date Name / name Maßangaben in
edited 27.05.04 M. Schmid checked 23.04.08 D.Müller dimension units mm
Projektion / projection : Maßstab / scale: Benennung / name:
1:1 SKINTOP MS-M Beipackzettel
SKINTOP MS-M operating instuction
Zeichnungs-Nr. / drawing no.: Blatt Dok. Art
05 500000001032 Mast1 26.03.2009 sheet: doc. type

Ind. Änderungs-Nr. Datum /date LAPP GROUP

U.I. Lapp GmbH BS04_2889 1/1 LBZ
DIN A 4
vs change number Bearb./edited Gepr./check. Ersatz für / substitute for: BS04_2889-3
 Wachendorff Automation GmbH & Co. KG
Industriestraße 7 • D-65366 Geisenheim
WDG100H-xx-yyyy-ABN-I05-K3-D56-zzz Tel.: +49(0)672 2 /99 65 -25
xx = Ø 25, 25.4, 28, 30, 38, 40, 42, 45 Fax: +49(0)672 2 /99 65-70
yyyy = PPR = 1024, 2048, 4096 eMail: wdg@wachendorff.de
zzz = 130 = 13m, 200 = 20m, blank = 10m www.wachendorff-automation.de
D56

Kabel, Steckergehäuse/Schirm
cable,
1 2 3 4 5
Câble,
mit Gebergehäuse leitend
6 7 8 9
Cable, verbunden
cavo
Connector housing/shield
SUBD9 K3 electrically connected to
9-pin encoder housing
7 WH
9 Bôtier de connexion/Ecran avec
BN
boîtier d’ementteur liés de
2 GN manière conductrice
3 YE
5 GY Caja de conector/Pantalls
conectada en conductancia com
caja de transmisor

1 RD scatola prese/Schemo con

4 scatola transmettitore collegata
BK
da condure 4,2

6 VT
4,2
-

Litze, Flex,
Toron,
8 Cordón,
Cavetto

TTL / RS422
5
1 2 3 4 5
6 7 8 9

31,8
25

39,5
15,4
UNC 4/40

46,5

Technical Support
Germany:
Tel.: +49 (0) 67 22 / 99 65 131
Fax: +49 (0) 67 22 / 99 65 70
email: support-wdgi@wachendorff.de

Other countries, please contact your distributor.

Autres pays, veuillez contacter votre distributeur.
Otros paises, rogamos contacten a su distribuidor.
Per gli altri paesi si prega di contattare il vostro
distributore.

18.08.2016
Drehgeber WDG 100H
www.wachendorff-automation.de/wdg100h

Wachendorff Automation
... Systeme und Drehgeber
• Komplette Systeme
• Industrierobuste Drehgeber für Ihren Anwendungsfall
• Standardprogramm und Kundenversionen
• Höchste zulässige Lasten
• 48 Stunden Eilproduktion
• Fertigung in Deutschland
• Weltweites Distributoren-Netzwerk

WDG 100H Alle Angaben ohne Gewähr, Irrtümer und Änderungen vorbehalten. © Wachendorff Automation GmbH & Co. KG 30.10.2018 -1-
Drehgeber WDG 100H
• Robuster und extrem flacher Hohlwellengeber
für den Anbau an Leistungsmotoren
• Durchgehende Hohlwelle mit max. 45 mm Bohrung
• Voller Anschlussschutz bei 10 VDC bis 30 VDC
• Einfache Montage
• Hohe Schutzart IP54
• Bis zu 20.480 I/U
• Optional: -40 °C bis +80 °C,
Schutzart IP55 rundum

www.wachendorff-automation.de/wdg100h

Auflösung Wellendurchmesser Ø 35 mm
Max. Impulszahl bis 20480 I/U Wellenlänge L: 42 mm
Max. Wellenbelastung radial 200 N
Mechanische Daten Max. Wellenbelastung axial 100 N
Gehäuse
Flanschtyp Hohlwelle (durchgehend) Wellendurchmesser Ø 36 mm
Flanschmaterial Aluminium Wellenlänge L: 42 mm
Flanschmaterial Rückseite Aluminium, beschichtet Max. Wellenbelastung radial 200 N
Drehmomentstütze inkl. 1 Drehmomentstütze Max. Wellenbelastung axial 100 N
WDGDS10001
- 1. Federblechausgleich axial: ±0,8 mm, radial: ±0,2 mm
Wellendurchmesser Ø 38 mm
Gehäusedurchmesser Ø 100 mm
Wellenlänge L: 42 mm
Max. Wellenbelastung radial 200 N
Welle(n)
Max. Wellenbelastung axial 100 N
Wellenmaterial Edelstahl
Anlaufdrehmoment ca. 1,5 Ncm bei Raumtemperatur
Wellendurchmesser Ø 40 mm
Befestigung 2 x M4, DIN 913;
Anzugsdrehmoment: 2,5 Nm Wellenlänge L: 42 mm
Max. Wellenbelastung radial 200 N
Wellendurchmesser Ø 25 mm Max. Wellenbelastung axial 100 N
Wellenlänge L: 42 mm
Max. Wellenbelastung radial 200 N Wellendurchmesser Ø 42 mm
Max. Wellenbelastung axial 100 N Wellenlänge L: 42 mm
Max. Wellenbelastung radial 200 N
Wellendurchmesser Ø 25,4 mm Max. Wellenbelastung axial 100 N
Wellenlänge L: 42 mm
Max. Wellenbelastung radial 200 N Wellendurchmesser Ø 45 mm
Max. Wellenbelastung axial 100 N Wellenlänge L: 42 mm
Max. Wellenbelastung radial 200 N
Wellendurchmesser Ø 28 mm Max. Wellenbelastung axial 100 N
Wellenlänge L: 42 mm
Max. Wellenbelastung radial 200 N Lager
Max. Wellenbelastung axial 100 N Lagertyp 2 Präzisionskugellager
Lebensdauer 3 x 10'10 U bei 100 % Lagerlast
1 x 10'11 U bei 40 % Lagerlast
Wellendurchmesser Ø 30 mm 1 x 10'12 U bei 20 % Lagerlast
Wellenlänge L: 42 mm Max. Betriebsdrehzahl 3500 min'-1
Max. Wellenbelastung radial 200 N
Max. Wellenbelastung axial 100 N Kenndaten für funktionale Sicherheit
MTTFd 200 a
Wellendurchmesser Ø 32 mm Gebrauchsdauer (TM) 25 a
Wellenlänge L: 42 mm Lebensdauer Lager (L10h) 1 x 10'12 U bei 20 % Lagerlast und
Max. Wellenbelastung radial 200 N 3500 min'-1
Max. Wellenbelastung axial 100 N Diagnosedeckungsgrad (DC) 0 %

WDG 100H Alle Angaben ohne Gewähr, Irrtümer und Änderungen vorbehalten. © Wachendorff Automation GmbH & Co. KG 30.10.2018 -2-
Elektrische Daten
Betriebsspannung/ 4,75 VDC bis 5,5 VDC: typ. 100 mA
Eigenstromaufnahme
Betriebsspannung/ 5 VDC bis 30 VDC: typ. 70 mA
Eigenstromaufnahme
Betriebsspannung/ 10 VDC bis 30 VDC: typ. 100 mA
Eigenstromaufnahme
Ausgangsschaltung TTL
TTL, RS422 kompatibel, inv.
HTL
HTL, inv.
1 Vss Sin/Cos
Impulsfrequenz TTL bis 5000 I/U: max. 200 kHz
HTL bis 5000 I/U: max. 200 kHz
TTL über 1200 I/U: max. 2 MHz
HTL über 1200 I/U: max. 600 kHz
1 Vss Sin/Cos: max. 100 kHz
Kanäle AB
ABN
und invertierte Signale
Belastung max. 40 mA / Kanal
bei 1 Vss Sin/Cos: min. 120 Ohm
Anschlussschutz nur bei H24 und R24

Genauigkeit
Phasenversatz 90° ± max. 7,5 % einer Teilungslänge
Impuls-/Pausenverhältnis ≤5000 I/U: 50 % ± max. 7 %
Ausgangsschaltungen F24, P24, F05,
P05, 645: 50 % max. ±10 %

Allgemeine Daten
Gewicht ca. 720 g
Anschluss radialer Kabel- oder Steckerabgang
Schutzart (EN 60529) IP54
Arbeitstemperatur -20 °C bis +80 °C
1 Vss: -10 °C bis +70 °C
Lagerungstemperatur -30 °C bis +80 °C

Weitere Informationen
Allgemein technische Daten und Sicherheitshinweise
http://www.wachendorff-automation.de/atd
Passendes Zubehör
http://www.wachendorff-automation.de/zub

WDG 100H Alle Angaben ohne Gewähr, Irrtümer und Änderungen vorbehalten. © Wachendorff Automation GmbH & Co. KG 30.10.2018 -3-
Kabelanschluss K3, L3 mit 2 m Kabel

Beschreibung ABN inv. möglich

K3 radial, Schirm offen •
L3 radial, Schirm mit Gebergehäuse leitend verbunden •

Anschlussbelegungen
K3, L3 K3, L3 L3 L3
Schaltung F05, H05, P05, R05, SIN SIF
F24, H24, P24, R24,
H30 245, 645,
R30
GND WH WH WH WH
+UB BN BN BN BN
A GN GN GN GN
B YE YE GY GY
N GY GY BK BK
Frühwarnausgang - - - RD
A inv. - RD YE YE
B inv. - BK, (BU PK PK
bei ACA)
N inv. - VT VT VT
Schirm Litze Litze Litze Litze

WDG 100H Alle Angaben ohne Gewähr, Irrtümer und Änderungen vorbehalten. © Wachendorff Automation GmbH & Co. KG 30.10.2018 -4-
Stecker (M16x0,75) SH, 5-, 6-, 8-, 12-polig

Beschreibung ABN inv. möglich

SH5 radial, 5-polig, Stecker mit Gebergehäuse leitend verbunden -
SH6 radial, 6-polig, Stecker mit Gebergehäuse leitend verbunden -
SH8 radial, 8-polig, Stecker mit Gebergehäuse leitend verbunden •
SH12 radial, 12-polig, Stecker mit Gebergehäuse leitend verbunden •

Anschlussbelegungen
SH5 SH6 SH8 SH8 SH8 SH12 SH12 SH12
5-polig 6-polig 8-polig 8-polig 8-polig 12-polig 12-polig 12-polig

Schaltung F05, H05, F05, H05, F05, H05, P05, R05, SIN P05, R05, F05, H05, SIN
F24, H24, F24, H24, F24, H24, P24, R24, P24, R24, F24, H24,
H30 H30 H30 R30, 245, 245, 645, H30
645 R30
GND 1 6 1 1 1 K, L K, L K, L
+UB 2 1 2 2 2 M, B M, B M, B
A 3 2 3 3 3 E E E
B 4 4 4 4 4 H H H
N 5 3 5 5 5 C C C
Frühwarnausgang - - - - - - - -
A inv. - - - 6 6 F - F
B inv. - - - 7 7 A - A
N inv. - - - 8 8 D - D
n. c. - 5 6, 7, 8 - - G, J A, D, F, G, J
G, J
Schirm - - - - - - - -

WDG 100H Alle Angaben ohne Gewähr, Irrtümer und Änderungen vorbehalten. © Wachendorff Automation GmbH & Co. KG 30.10.2018 -5-
Stecker (M16x0,75) S3, 7-polig

Beschreibung ABN inv. möglich

S3 radial, 7-polig, Stecker mit Gebergehäuse leitend verbunden -

Anschlussbelegungen
S3
7-polig

Schaltung F05, H05,

F24, H24,
H30
GND 1
+UB 2
A 3
B 4
N 5
Frühwarnausgang -
A inv. -
B inv. -
N inv. -
n. c. 6, 7
Schirm -

WDG 100H Alle Angaben ohne Gewähr, Irrtümer und Änderungen vorbehalten. © Wachendorff Automation GmbH & Co. KG 30.10.2018 -6-
Stecker (M23) S5, 12-polig

Beschreibung ABN inv. möglich

S5 radial, 12-polig, Stecker mit Gebergehäuse leitend verbunden •

Anschlussbelegungen
S5 S5 S5 S5
12-polig 12-polig 12-polig 12-polig

Schaltung F05, H05, P05, R05, SIN SIF

F24, H24, P24, R24,
H30 245, 645,
R30
GND 10 10 10 10
+UB 12 12 12 12
A 5 5 5 5
B 8 8 8 8
N 3 3 3 3
Frühwarnausgang - - - 7
A inv. - 6 6 6
B inv. - 1 1 1
N inv. - 4 4 4
n. c. 1, 2, 4, 6, 2, 7, 9, 11 2, 7, 9, 11 2, 9, 11
7, 9, 11
Schirm - - - -

WDG 100H Alle Angaben ohne Gewähr, Irrtümer und Änderungen vorbehalten. © Wachendorff Automation GmbH & Co. KG 30.10.2018 -7-
Stecker (M23) S5R, 12-polig (rechtsdrehend)

Beschreibung ABN inv. möglich

S5R radial, 12-polig, Stecker mit Gebergehäuse leitend verbunden •

Anschlussbelegungen
S5R S5R S5R S5R
12-polig 12-polig 12-polig 12-polig

Schaltung F05, H05, P05, R05, SIN SIF

F24, H24, P24, R24,
H30 245, 645,
R30
GND 10 10 10 10
+UB 12 12 12 12
A 5 5 5 5
B 8 8 8 8
N 3 3 3 3
Frühwarnausgang - - - 7
A inv. - 6 6 6
B inv. - 1 1 1
N inv. - 4 4 4
n. c. 1, 2, 4, 6, 2, 7, 9, 11 2, 7, 9, 11 2, 9, 11
7, 9, 11
Schirm - - - -

WDG 100H Alle Angaben ohne Gewähr, Irrtümer und Änderungen vorbehalten. © Wachendorff Automation GmbH & Co. KG 30.10.2018 -8-
Sensor-Stecker (M12x1) SC, 4-, 5-, 8-polig

Beschreibung ABN inv. möglich

SC4 radial, 4-polig, Stecker mit Gebergehäuse leitend verbunden -
SC5 radial, 5-polig, Stecker mit Gebergehäuse leitend verbunden -
SC8 radial, 8-polig, Stecker mit Gebergehäuse leitend verbunden •

Anschlussbelegungen
SC4 SC5 SC8 SC8 SC8
4-polig 5-polig 8-polig 8-polig 8-polig

Schaltung F05, H05, F05, H05, F05, H05, P05, R05, SIN
F24, H24, F24, H24, F24, H24, P24, R24,
H30 H30 H30 R30, 245,
645
GND 3 3 1 1 1
+UB 1 1 2 2 2
A 2 4 3 3 3
B 4 2 4 4 5
N - 5 5 5 7
Frühwarnausgang - - - - -
A inv. - - - 6 4
B inv. - - - 7 6
N inv. - - - 8 8
n. c. - - 6, 7, 8 - -
Schirm - - - - -

WDG 100H Alle Angaben ohne Gewähr, Irrtümer und Änderungen vorbehalten. © Wachendorff Automation GmbH & Co. KG 30.10.2018 -9-
Optionen

Niedrig Temperatur Bestell-Code

Der Drehgeber WDG 100H mit den Ausgangsschaltungen F24, H24, P24, R24, F05, H05, ACA
P05, R05, 245, 645 ist auch mit dem erweiterten Temperaturbereich -40 °C bis +80 °C
(gemessen am Flansch) lieferbar.

IP55 rundum (nicht bei 1 Vss Sin/Cos) Bestell-Code

Der Drehgeber WDG 100H ist auch mit der hohen Schutzart IP55 rundum lieferbar. ACP

Max. Betriebsdrehzahl: 1500 min'-1

Zulässige Wellenbelastung, axial: 100 N
Zulässige Wellenbelastung, radial: 120 N
Max. Impulszahl: 5000 I/U
Anlaufdrehmoment: ca. 5 Ncm bei Raumtemperatur

Kabellänge Bestell-Code
Der Drehgeber WDG 100H ist auch mit mehr als 2 m Kabel erhältlich. Die max. XXX = Dezimeter
Kabellänge ist abhängig von der Betriebsspannung und der Frequenz; siehe www.
wachendorff-automation.de/atd
Bei der Bestellung ergänzen Sie bitte die Bestellnummer mit einer 3-stelligen Ziffer welche
die Länge in Dezimeter angibt.
Beispiel: 5 m Kabellänge = 050

WDG 100H Alle Angaben ohne Gewähr, Irrtümer und Änderungen vorbehalten. © Wachendorff Automation GmbH & Co. KG 30.10.2018 -10-
Beispl. Bestell-Nr. Typ Ihr Drehgeber
WDG 100H WDG 100H WDG 100H

Hohlwellendurchmesser
25 25; 1Z=Ø 25,4 mm,Ø 1"; 28; 30; 32; 35; 36; 38; 40; 42; 45

Impulszahlen:
1024 512, 1024, 2048, 2500, 3600, 4096, 4500, 5000, 8192, 10240, 16384, 20480
1 Vss Sin/Cos nur bei 1024, 2048
Andere Impulszahlen auf Anfrage

Impulsfolge:
ABN AB, ABN

Ausgangsschaltung
Auflösung Betriebs- Ausgangsschaltung Frühwarn- Bestellschlüssel
I/U spannung VDC ausgang
5 - 30 HTL - H30
bis 2500
5 - 30 HTL invertiert - R30
4,75 - 5,5 TTL - H05
4,75 - 5,5 TTL, RS422 komp., invertiert - R05
bis 5000 10 - 30 HTL - H24
10 - 30 HTL invertiert - R24
H24
10 - 30 TTL, RS422 komp., invertiert - 245
4,75 - 5,5 TTL - F05
4,75 - 5,5 TTL, RS422 komp., invertiert - P05
8192 bis
10 - 30 HTL - F24
20480
10 - 30 HTL invertiert - P24
10 - 30 TTL, RS422 komp., invertiert - 645
4,75 - 5,5 1 Vss Sin/Cos • SIF
1024, 2048
4,75 - 5,5 1 Vss Sin/Cos - SIN

Elektrischer Anschluss
Beschreibung ABN inv. mögl. Bestellschlüssel
Kabel: Länge (2 m Standard, WDG 58T: 1 m)
radial, Schirm offen • K3
radial, Schirm mit Gebergehäuse leitend verbunden • L3
Stecker: (Stecker mit Gebergehäuse leitend verbunden)
Stecker, M16x0,75, 5-polig, radial - SH5
Stecker, M16x0,75, 6-polig, radial - SH6
K3 Stecker, M16x0,75, 8-polig, radial • SH8
Stecker, M16x0,75, 12-polig, radial • SH12
Stecker, M16x0,75, 7-polig, radial - S3
Stecker, M23, 12-polig, radial • S5
Stecker, rechtsdrehend, M23, 12-polig, radial • S5R
Sensorstecker, M12x1, 4-polig, radial - SC4
Sensorstecker, M12x1, 5-polig, radial - SC5
Sensorstecker, M12x1, 8-polig, radial • SC8

Optionen
Beschreibung Bestellschlüssel
Keine Option gewählt Leer
Niedrig Temperatur ACA
IP55 ACP
Kabellänge XXX = Dezimeter

Bsp-Bestell-Nr.= WDG 100H 25 1024 ABN H24 K3 WDG 100H Ihr Drehgeber

WDG 100H Alle Angaben ohne Gewähr, Irrtümer und Änderungen vorbehalten. © Wachendorff Automation GmbH & Co. KG 30.10.2018 -11-
Ansprechpartner

Für technische Fragen

(Anwendungsberatung, Anpassungsentwicklung, inkrementale Drehgeberauswahl)
wenden Sie sich bitte an:

Technische Anwendungsberatung inkrementale Drehgeber

Thomas Post
Tel: +49 6722 9965131
Fax: +49 6722 996570
E-Mail: support-wdgi@wachendorff.de

Für kaufmännische Fragen und Angebote

wenden Sie sich bitte an:

Vertriebsinnendienst
Tatjana Weigelt
Tel: +49 6722 9965242
Fax: +49 6722 996570
E-Mail: sales-wa@wachendorff.de

Im deutschsprachigen Ausland
wenden Sie sich bitte an:

Ihren Distributor

https://www.wachendorff-automation.de/distributoren.html

Wachendorff Automation GmbH & Co. KG

Industriestrasse 7 • D-65366 Geisenheim

Tel: +49 67 22 / 99 65 25
Fax: +49 67 22 / 99 65 70
E-Mail: wdg@wachendorff.de
www.wachendorff-automation.de

WDG 100H Alle Angaben ohne Gewähr, Irrtümer und Änderungen vorbehalten. © Wachendorff Automation GmbH & Co. KG 30.10.2018 -12-
 WDG100H-xx-yyyy-ABN-R05-L3-CTF-zzz
xx = Ø = 25, 28, 38, 42, 45mm
yyyy = PPR, 1024, 2048, 4096
zzz = 100= 10m, 050 = 5m, 200 = 20m, blank = 2m

*1
1 5 Kabel, Steckergehäuse/Schirm
6 10 cable,
11 15
mit Gebergehäuse leitend
Câble,
Cable, verbunden
cavo (Nicht S7, K1, K2, K3)
SUB-D Connector housing/shield
15-pin electrically connected to
encoder housing
14 WH (not S7, K1, K2, K3)
13 BN Bôtier de connexion/Ecran avec
1 GN boîtier d’ementteur liés de
manière conductrice
3 GY
(No S7, K1, K2, K3)
5 BU
Caja de conector/Pantalls
conectada en conductancia com
caja de transmisor
(No S7, K1, K2, K3)
2 YE
scatola prese/Schemo con
4 PK scatola transmettitore collegata
6 RD da condure
(No S7, K1, K2, K3)
7, 8, 9, 10, -
11, 12, 15
*1 Litze, Flex,
Toron,
- Cordón,
Cavetto

, ,
,
TTL / RS422
-
BU:

Technical Support
Germany:
Tel.: +49 (0) 67 22 / 99 65 77
Fax: +49 (0) 67 22 / 99 65 70
email: support-wdg@wachendorff.de

Other countries, please contact your distributor.

Autres pays, veuillez contacter votre distributeur.
Otros paises, rogamos contacten a su distribuidor.
Per gli altri paesi si prega di contattare il vostro
distributore.

21.10.2014

Ausdruck unterliegt nicht dem Änderungsdienst PP99500012375 AFG 001 00 FR 13.07.2020 HEIMERDING.D
Encoder WDG 100H-38-2048-ABN-245-L3-AJE-030

Resolution Output circuit TTL, RS422 comp., inverted

Pulses per revolution PPR 2048 ppr Channels ABN
Output push-pull
Mechanical Data Load max. 40 mA / channel
Housing Signal level mA at 20 mA
Flange hollow shaft (through-bored) Signal level H> H > 2.5 VDC
Flange material aluminum Signal level L< L < 1.2 VDC
Housing cap aluminum, powder coated Output frequency max. 200 kHz
Torque supports without torque support Circuit protection inverse-polarity protection only
Light reserve warning no

Housing Ø 100 mm
General Data
Weight approx. 720 g
Shaft(s)
Connections cable, radial
Shaft material stainless steel
Protection rating (EN 60529) IP55
Starting torque approx. 1.5 Ncm at ambient
temperature Operating temperature -20 °C up to +80 °C
Fixing 2 x M4, DIN 913;
Starting torque: 2,5 Nm Storage temperature -30 °C up to +80 °C

Shaft Ø 38 mm More Information

Shaft length L: 42 mm General technical data and safety instructions
http://www.wachendorff-automation.com/gtd
Max. Permissible shaft 200 N
loading radial Options
http://www.wachendorff-automation.com/acc
Max. Permissible shaft 100 N
loading axial

Bearings
Bearings type 2 precision ball bearings
Nominale service life 3 x 10'10 revs. at 100 % rated shaft
load
1 x 10'11 revs. at 40 % rated shaft
load
1 x 10'12 revs. at 20 % rated shaft
load
Max. operating speed 3500 rpm

Machinery Directive: basic data safety integrity level

MTTFd 200 a
Mission time (TM) 25 a
Nominale service life (L10h) 1 x 10'12 revs. at 20 % rated shaft
load and 3500 rpm
Diagnostic coverage (DC) 0%

Electrical Data
Power supply VDC 10 - 30 VDC
Current consumption typ. 70 mA
Signal shape square-wave

WDG 100H Errors and modifications reserved. © Wachendorff Automation GmbH & Co. KG 2022-04-19 -1
-
Cable connection K3, L3 with 20 dm cable

Description ABN inv. poss.

L3 radial, shield connected to encoder housing •

Assignments
L3
Circuit 245
GND WH
(+) Vcc BN
A GN
B YE
N GY
Light reserve -
warning
A inv. RD
B inv. BK
N inv. VT
Shield flex

WDG 100H Errors and modifications reserved. © Wachendorff Automation GmbH & Co. KG 2022-04-19 -2-
Example Order No. Type Your encoder
WDG 100H WDG 100H WDG 100H

Bore size
38 38 38

Pulses per revolution PPR:

2048 2048 2048

Channels:
ABN ABN ABN

Output circuit
Resolution Power supply Output circuit Light reserve Order key
245 PPR VDC warning 245
up to 5000 10 - 30 TTL, RS422 comp., inverted - 245

Electrical connections
Description ABN inv. poss. Order key
L3 Cable: length (2 m standard, WDG 58T: 1 m) L3
radial, shield connected to encoder housing • L3

Options
IP55, with ferrules, without torque support, Order key
AJE-xxx AJE-xxx
xxx= cable length in dm (without xxx= 20 dm) AJE

Example Order No.= WDG 100H 38 2048 ABN 245 L3 AJE WDG 100H 38 2048 ABN 245 L3 AJE Your encoder

For further information please contact our local distributor.

Here you find a list of our distributors worldwide.
https://www.wachendorff-automation.com/

Wachendorff Automation GmbH & Co. KG

Industriestrasse 7 • 65366 Geisenheim
Germany

Phone: +49 67 22 / 99 65 25
Fax: +49 67 22 / 99 65 70
E-Mail: wdg@wachendorff.de
www.wachendorff-automation.de

WDG 100H Errors and modifications reserved. © Wachendorff Automation GmbH & Co. KG 2022-04-19 -3-
 129

TK Elevator
BA, TW45 | 6231003860 | 03/2023
130

TK Elevator
BA, TW45 | 6231003860 | 03/2023
 131

TK Elevator
BA, TW45 | 6231003860 | 03/2023
TK Aufzugswerke GmbH
Bernhäuser Straße 45
73765 Neuhausen a.d.F., Germany
P: +49 7158 12-0
doku.elevator.plant.de@tkelevator.com

03/2023